Fast and accurate Zero-defect manufacturing using collaborative real-time photogrammetry

Abstract. For the machining of industrial components, their accurate alignment on operative machines is a crucial step with significant impacts on the whole process, especially when dealing with large-scale elements. To achieve this alignment, a trained operator is needed along with expensive equipment, such as laser trackers, whose correct use requires the measurements of many significant points and is time-consuming. The lack of a precise alignment comes with possible incorrect parts machining, resulting in quality concerns and potentially expensive rework. To face this problem, collaborative real-time photogrammetry is an effective solution for guiding untrained users in correctly positioning various measured and codified components to generate the best solution for machining high-volume parts. The solution proposed in this contribution is part of the TACCO project, co-financed by EIT Manufacturing (co-funded by the EU). It takes advantage of the TACCO system, where auxiliary components (scale bars, dome-shaped components, coded targets and a cross-reference system) are placed on the object to be measured for their correct positioning in order to obtain an optimal photogrammetric reconstruction. This allows the reduction of the error ellipsoids on several uncoded targets, which are calculated through an iterative simulation carried out in a MATLAB environment. Unskilled operators are then guided through an Augmented Reality headset for their correct placement on the real-world object and for defining the positions and orientations from which to acquire images. This methodology will lead to an accurate measurement of the target points to be machined and, thus, a precise alignment process for the subsequent machining operations.