EXPLORING THE LIMITS OF TERRESTRIAL LASER SCANNERS ON AEROSPACE MATERIALS

Abstract. Terrestrial laser scanners are powerful measurement devices commonly used for 3D modelling tasks generating large volumes of data with fast acquisition as a first priority. However, these scanners can alternatively be used to produce near real-time, engineering quality spatial data concerning the changing state of manufactured components. This paper provides a comprehensive analysis of two terrestrial laser scanners capturing aerospace materials and components, and their associated quality measures. In order to explore the limitations of the tested TLS instruments, a mechanical jig was designed incorporating both a rotation and translation stage. This study involved three elements of a point cloud processing workflow: data capture, registration and feature extraction. Sphere-based 7DoF registration is applied using two different commercially available software packages with varying levels of user control. To analyse the quality of the registration, control points extracted from captured point clouds were compared to nominal values measured using a laser tracker. The quality of the registration was consistent, with differences kept between 0.4 mm and 0.6 mm. To evaluate the quality of the captured point clouds, two different tests were conducted. This included planar fit tests on an aluminium drilling template, and sphere fitting tests on white 1.5” spherical targets in magnetic nests. One half of the aluminium drilling template was coated with matte spray to reduce erroneous laser reflections. Finally, the registered point clouds were input to a developed algorithm which automatically extracted drilling holes from the drilling template. Previous scanning work performed on aerospace materials showed evidence of optical rattling caused by high intensity reflections from the interior holes in a drilling template. Further exploration showed that the amount of optical rattle varies systematically with incidence angle. This work demonstrates a systematic offset in the location of extracted hole centres in the drilling template. This offset is dependent on laser incidence angle, and can therefore be accounted for when locating manufacturing components from a known scanning position.