We as 3D.aero are developing a relatively inexpensive stereo camera system for industrial applications that meets the requirements of the BiSconA use-case, but could also be adapted to several more.In our solution we are using smartphone cameras in a self-built camera system, an easy calibration procedure and a self-developed referencing system, in order to be able to measure the side shell of an aircraft.
Our development uses MiPi-cameras with a 12MPx resolution, a base partly made of carbon and CS-mount (with adapters to C-mount). The transformation into the needed coordinate system will be obtained by a moveable reference frame, which will be placed between the camera system and the object to be measured. This frame will also serve as a mounting for the (IR-) flash as well as be used for on-site recalibration, since the stereo camera systems are very hard to reach, once they have been mounted. This will allow us to keep track of the measurement accuracies and do a re-calibration if needed, without a lot of effort. An initial calibration will be done before mounting in-lab using our own calibration software.
In BiSconA we are able to measure existing features on the shell surface with absolute accuracies below 0.1 mm with respect to plant coordinate system and also extract the interface edges into a 3D point cloud, using self-developed image processing software, which can be adapted to many more use-cases. The measurement data will be provided via a server and is getting updated every 3 seconds.
In conclusion, we can measure an aircraft side-shell in below-mm resolution, while using smartphone cameras and reducing the overall costs by up to 80%.