Optimal shape error analysis of the matching image for a free-form surface

When using an optical non-contact scanning system to measure an object that has a large surface, large curvature, or a full 360 profile, one can acquire only one set of sectional measurement points each time. For reconstructing the entire object, every set of sectional measurement points acquired at different positions must match. Therefore, the optimal shape error analysis for the matching image of two or more sets of sectional measurement points is desired. This paper presents a measurement system that combines two CCD cameras, one line laser and a three-axis motion stage. It forms an optical non-contact scanning system in association with the mathematical method of direct shape error analysis for the use in reverse engineering. This analysis and measurement system can be used for the profile measurements of free-form objects. It analyzes the matching image of a free-form surface with high efficiency and accuracy. The validity and applicability of this system are demonstrated by two practical examples. (C) 2001 Elsevier Science Ltd. All rights reserved.