Hitachi Energy is a world leading company in the production and installation of power transformers and the quality of their services is of the utmost importance. The majority of the company's current quality control methods are performed manually, the purpose of this study is to identify potential areas where the use of 3D-scanning technology as a method for quality control has potential, making use of interviews, literature studies and document analysis to do so. Further the study wishes to outline the specific methods that could be used to increase the efficiency of the production and present the steps that would be required for these methods to be implemented effectively.  The results revealed that both the active core and final assembly processes currently face issues. The active core assembly with specific aluminum pipes that often differ from the specified tolerances. Most of these problems come from external suppliers and get noticeable when they arrive at the active core assembly. The final assembly faces issues with the lowering down of the active core into its container. A process that can vary drastically in the time it takes while simultaneously being a very time sensitive process. The study proposes three methods as solutions to these problems. An initial control of the aluminum pipes after delivery with FARO:s Quantum Max ScanArm and CAM2 Software. As well as a simulated lowering down of the active core, making use of FARO:s Focus Laser Scanner and the software program SCENE. Lastly, a more general use of 3D-scanning for quality control. It is concluded that committing to an investment is required to reach further results.

Laser powder bed fusion is one of the most effective ways to achieve metal additive manufacturing. However, this method still suffers from deformation, delamination, dimensional error, and porosities. One of the most significant issues is poor printing accuracy, especially for small features such as turbine blade tips. The main reason for the shape inaccuracy is the heat accumulation caused by using constant laser power regardless of the shape variations. Due to the highly complex and dynamic nature of the laser powder bed fusion, improving the printing quality is challenging. Research gaps exist from many perspectives. For example, the lack of understanding of multi-physical melt pool dynamics fundamentally impedes the research progress. The scarcity of a customizable laser powder bed platform further restricts the possibility of testing the improvement strategies. Additionally, most state-of-the-art quality inspection techniques suitable for laser powder bed fusion are costly in economic and time aspects. Lastly, the rapid and chaotic printing process is hard to monitor and control. This dissertation proposes a complete research scheme including a fundamental physics study, process signature and quality correlation, smart additive manufacturing platform development, high-performance sensor development, and a robust real-time closed-loop control system design to address all these issues. The entire research flow of this dissertation is as follows: 1. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the melt pool dynamics, keyhole, porosity formation, vapor plume, and thermal evolution in Ti-64 and 410 stainless steel. The study discovers a strong correlation between the thermal and X-ray data, enabling the feasibility of using relatively cheap IR cameras to predict features that can only be captured using costly synchrotron X-ray imaging. Such correlation is essential for thermal-based melt pool control. 2. A highly customizable smart laser powder bed fusion platform is designed and constructed. This platform integrates numerous sensors, including but not limited to co-axial cameras, IR cameras, oxygen sensors, photodiodes, etc. The platform allows in-process parameter adjusting, which opens the boundary to test various control theories based on multi-sensing and data correlations. 3. To fulfill the quality assessment need of laser powder bed fusion, this dissertation proposes a novel structured light 3D scanner with extraordinary high spatial resolution. The spatial resolution and accuracy are improved by establishing hardware selection criteria, integrating the proper hardware, designing a scale-appropriate calibration target, and developing noise reduction procedures during calibration. Compared to the commercial scanner, the proposed scanner improves the spatial resolution from 48 µm to 5 µm and the accuracy from 108.5 µm to 0.5 µm. 4. The final goal of quality improvement is achieved through designing and implementing a real-time closed-loop system into the smart laser powder bed fusion platform. The system regulates the laser power based on the monitoring result from a novel thermal sensor. The desired printing temperature is found by correlating the laser power, the dimensional accuracy, and the thermal signatures from a set of thin-wall structure printing trails. An innovative high-speed data acquisition and communication software can operate the whole system with a graphic user interface. The result shows the laser power can be successfully controlled with 2 kHz, and a significant improvement in small feature printing accuracy has been observed. / Doctor of Philosophy / Laser powder bed fusion is one of the most effective ways to achieve metal additive manufacturing. However, this method still suffers from defects such as deformation, delamination, dimensional error, and porosities. Due to the highly complex and dynamic nature of the laser powder bed fusion, improving the printing quality is challenging. Research gaps exist from many perspectives, such as the lack of understanding of melt pool dynamics; the scarcity of a customizable laser powder bed platform; the need for suitable sensors; and the missing of a control system that can effectively regulate the rapid and chaotic printing process. This dissertation proposes a complete research scheme to address all these issues. The fundamental study characterizes the melt pool dynamics and discovers a strong correlation between the melt pool thermal and geometrical data, enabling thermal-based melt pool control. Following that, a highly customizable smart laser powder bed fusion platform is designed and constructed. The platform allows in-process parameter changes, opening the boundary to test various control theories. A novel structured light 3D scanner with an ultra-high spatial resolution was proposed to fulfill the quality assessment need. The final goal of quality improvement is achieved through designing and implementing a real-time closed-loop system into the smart laser powder bed fusion platform. The system regulates the laser power based on real-time thermal monitoring. The result shows the laser power can be successfully controlled with 2 kHz, and a significant improvement in printing accuracy is achieved.

This report has been written to analyze a newly acquired measurement method within the companyAston Harald Mekaniska Verkstad AB, which is a 3D scanner made by the company Creaform. Thismodel bought has the name Metrascan 3D Black Elite. 3D scanning is an optical measurement methodwhich uses light to create a mesh of a measured object, where it is later compared to a nominal CAD filein the software Polyworks Inspector. To verify this method of measurement, it will be compared to twoother known calibrated and verified methods, which are coordinate measuring machines (CMM) andregular measuring instruments, which includes several kinds of micrometers and general anglemeasuring devices. To analyze and compare these methods an amount of data will be collected, and willbe used to conduct statistical analysis, where the mean/median, normal distribution, standarddeviation, and confidence intervals are included. The report will analyze two different kinds of data,where the first set consists of regular geometries such as linear and circular measurements, as well asseveral kinds of GD&T (Geometric Dimensions and Tolerances). The second set involves more complexgeometries according to the ISO standard ISO 484. The first set of data will be analyzed using amanufactured reference object, made using the aluminum alloy AL-7020 T6. The second set will beanalyzed using a propeller blade borrowed from the company Kongsberg. The results from this reportshow that 3D scanning is not as accurate nor as precise compared to CMM measurement and regularhand measuring instruments and cannot replace these measuring methods entirely. An empiricalformula has been derived from the analyzed data, and tolerance intervals are recommended to beincreased by approximately 0.1 to 1.0 % percent for regular linear and circular measurements dependingon the size of the detail measured. and upwards of 200 percent for GD&T tolerance intervals. However,3D scanning shows a greater promise when it comes to scanning propeller blades, as most measurementpoints were within specification according to the ISO 484 standard, and results can be further improved,such as with a tighter scanning mesh. Quality control and regulation is a topic whose discussion wasdesired, however, due to time constraints and the sensitivity of the scanner equipment, only an FMEAtable of potential error sources has been made for this report. Ergonomically some issues were found,particularly when it comes to static loading of arm muscles and repeated neck movement, both potentialsources for fatigue and injury. Recommended solutions for this include a flexible workstation whereboth the operator and the workpiece can be adjusted for optimal movement with minimal strain onpreviously mentioned body parts. Future improvements include performing a regression analysis ondifferent reference objects with many similar measurement types, for instance 50 holes with differentdiameters, which can lead to direct comparison formulas compared to nominal values. Furthermore,tests can be repeated with eliminating fault sources such as bad lightning.

Applications like military, agriculture, and extra-planetary explorations require the successful navigation of vehicles across different types of terrain like soil, mud, and snow. As the properties of the terrain heavily influence the interaction with the tire, it is necessary to characterize the terrain from a tire performance and vehicle mobility perspective. Failure to properly understand the tire-terrain interaction can lead to undesirable conditions like loss of vehicle mobility due to excessive sinkage. As a result, it is essential to understand the tire terrain interaction between an off-road tire and a sandy terrain. This study was done to assess the performance of tires in both pure slip (only traction and braking) and combined slip conditions (steering and acceleration). A single-wheel indoor test rig was used to conduct tests under different conditions and a force transducer was used to capture the forces and moments generated in the tire hub. In addition to this, the tire footprint was captured with the help of a light-based 3-D scanner. Key parameters were defined in the 3D scan, and these parameters were correlated to the input test conditions. Additionally, a grid of force sensors was made, and measurements of the normal force acting at a depth below the undisturbed terrain were taken. Inferences were made about the linear speed of the wheel and the length of the pressure bulb under the tire. / Master of Science / Several applications like military, extra-terrestrial exploration, and motor racing require vehicles to navigate off-road terrains like soil, snow, and ice. The tire interacts with these off-road terrains very differently from the way it interacts with the road. It is important to understand this interaction correctly as this interaction generates all the forces needed by a vehicle to perform various maneuvers like acceleration, braking, and turning. If not accounted for properly, there can be undesirable conditions like loss of vehicle mobility due to excessive sinkage in sand. Tests were performed where an off-road tire ran on a non-cohesive, loose soil under different slip ratios, slip angles, and camber angles in an indoor test rig. The forces and moments acting on the tire during the tests were measured and its variation with input conditions was studied. A light-based 3D scanner was used to capture the tire rut profile on the soil after each test. The important parameters of the tire rut were defined and the variation of these parameters with input parameters were studied. Additionally, the stresses developed below the soil surface were measured with the help of a sensor grid, which was also used to verify the linear speed of the tire and infer the length of the zone inside the soil that is affected by the tire.

Gegenstand der vorliegenden Dissertation ist die Entwicklung von Algorithmen und Methoden mit dem Ziel, Archäologen bei der täglichen wissenschaftlichen Arbeit zu unterstützen. Im Teil I werden Ideen präsentiert, mit denen sich die extrem zeitintensive und stellenweise stupide Funddokumentation beschleunigen lässt. Es wird argumentiert, dass das dreidimensionale Erfassen der Fundobjekte mittels Laser- oder Streifenlichtscannern trotz hoher Anschaffungskosten wirtschaftlich und vor allem qualitativ attraktiv ist. Mithilfe von nicht fotorealistischen Visualisierungstechniken können dann wieder aussagekräftige, aber dennoch objektive Bilder generiert werden. Außerdem ist speziell für Gefäße eine vollautomatische und umfassende Merkmalserhebung möglich. Im II. Teil gehen wir auf das Problem der automatisierten Gefäßklassifikation ein. Nach einer theoretischen Betrachtung des Typbegriffs in der Archäologie präsentieren wir eine Methodologie, in der Verfahren sowohl aus dem Bereich des unüberwachten als auch des überwachten Lernens zum Einsatz kommen. Besonders die letzteren haben sich dabei als überaus praktikabel erwiesen, um einerseits unbekanntes Material einer bestehenden Typologie zuzuordnen, andererseits aber auch die Struktur der Typologie selbst kritisch zu hinterfragen. Sämtliche Untersuchungen haben wir beispielhaft an den bronzezeitlichen Gräberfeldern von Kötitz, Altlommatzsch (beide Lkr. Meißen), Niederkaina (Lkr. Bautzen) und Tornow (Lkr. Oberspreewald-Lausitz) durchgeführt und waren schließlich sogar in der Lage, archäologisch relevante Zusammenhänge zwischen diesen Fundkomplexen herzustellen. / The topic of the dissertation at hand is the development of algorithms and methods aiming at supporting the daily scientific work of archaeologists. Part I covers ideas for accelerating the extremely time-consuming and often tedious documentation of finds. It is argued that digitizing the objects with 3D laser or structured light scanners is economically reasonable and above all of high quality, even though those systems are still quite expensive. Using advanced non-photorealistic visualization techniques, meaningful but at the same time objective pictures can be generated from the virtual models. Moreover, specifically for vessels a fully-automatic and comprehensive feature extraction is possible. In Part II, we deal with the problem of automated vessel classification. After a theoretical consideration of the type concept in archaeology we present a methodology, which employs approaches from the fields of both unsupervised and supervised machine learning. Particularly the latter have proven to be very valuable in order to assign unknown entities to an already existing typology, but also to challenge the typology structure itself. All the analyses have been exemplified by the Bronze Age cemeteries of Kötitz, Altlommatzsch (both district of Meißen), Niederkaina (district of Bautzen), and Tornow (district Oberspreewald-Lausitz). Finally, we were even able to discover archaeologically relevant relationships between these sites.

Ett styrsystem för 3D-scanning har moderniserats av en projektgrupp på nio personer. Under utvecklingsarbetet följdes en arbetsprocess som liknade vattenfallsmetoden. Arbetsprocessen fungerade bra, bland annat då projektgruppen utnyttjat både tidigare och nya erfarenheter för att förbättra arbetssättet. Systemet som utvecklades ersätter ett tidigare styrsystem baserat på Matlab, men behåller samma grundläggande uppsättning hårdvara. En avståndskamera, en linjärenhet och ett rotationsbord utgör grunden till systemet. Med hjälp av denna hårdvara möjliggör systemet 3D-scanningar av mindre objekt. Styrsystemet är utvecklat med Python och ROS, Robot Operating System. Valet av ROS ledde till en komplex arkitektur på grund av skillnader i systemkrav hos ROS och hårdvarudrivrutiner. Utan dessa systemkrav tros ROS ha varit ett ypperligt val. Den utvecklade arkitekturen jämförs med en alternativ hypotetisk arkitektur, vilken uppvisade lägre komplexitet och större portabilitet. Den är dock inte lika lättanvänd tillsammans med andra ROS-system. Under utvecklingsarbetet har modularitet, vidareutvecklingsbarhet och robusthet varit i fokus. Även om det fullständiga systemet inte är så robust som önskats så anses de ingående modulerna uppvisa en önskad nivå av robusthet. Systemet uppvisar även en hög grad av modularitet. Den utförligt dokumenterade koden tillsammans med de väl separerade modulerna har lett till att systemet bör vara lätt att vidareutveckla.

The thesis describes state of the art volumetric measurement techniques and applies a 3D measurement technique, 3D Scanning Particle Tracking Velocimetry, to the transitional backward facing step flow. The measurement technique allows the spatial and temporal analysis of coherent structures apparent at the backward facing step. The thesis focusses on the extraction and interaction of coherent flow structures like shear layers or vortical structures.

Automated, large-scale 3D-scanning systems are important tools in culture and heritage preservation that allows museums and art institutes to digitize their collections of movable artifacts for the purpose of preservation, research, and exhibition. Unfortunately, the cost of these systems limits their usage to a handful of wealthy museums and art institutes. This thesis explores if it possible to significantly reduce the cost of such a system by presenting a viable automated, large-scale, 3D-scanning system for movable artifacts tailored to the needs of museums and art institutes. To achieve the thesis goal a market analysis was conducted to identify the need and requirements museums and art institutes have for these kinds of systems. The market analysis also explored available systems on the market and how museums and art institutes use them. The result of the market analysis identified a specific type of automated, large-scale, 3D-scanning system design suitable for market specialization. Based on the market analysis requirements for such a system design were specified and developed into a mechanical design and hardware architecture. These were then used to construct and evaluate a limited prototype as a way of validating the mechanical design and hardware architecture. The remainder of the work consisted of a cost analysis which used the hardware architecture and mechanical designs to estimate the material and component cost to produce a single unit of the developed system. The results of this thesis show that it is probable that market specialization significantly reduces the cost for museums and art institutes to purchase an automated, large-scale, 3D-scanning system compared with available market alternatives. / Automatiserade 3D-scanners som kan 3D-scanna stora volymer av konstprodukter är viktiga verktyg inom kulturhistorisk bevaring då det tillåter museum att digitalisera samlingar i syfte att bevara, forska och ställa ut. Tyvärr så är dessa system dyra och bara ett fåtal museer har resurser nog för att köpa in dem. Denna uppsats utforskar ifall det är möjligt att betydligt reducera kostnaden av ett sådant system genom att presentera en fungerande automatiserad 3D-scanner som är specifikt anpassad för museum. Arbetet började med en marknadsanalys som identifierade kraven som museum ställer på denna typ av system samt en analys av tillgängliga system på marknaden och hur museum använder dessa. Resultatet av detta arbete var att en specifik typ av automatiserad 3D-scannar lämplig för anpassning identifierades. Utifrån kraven som identifierades genom marknadsanalysen så utvecklades sedan en mekanisk och elektrisk design för systemet. Dessa användes sedan för att bygga och utvärdera en begränsad prototyp i syfte att validera den mekaniska och elektriska designen. Resterande arbete bestod av en kostnadsanalys som använde den mekaniska och elektriska designen för att utvärdera material och komponentkostnaden för att bygga en enhet av det utvecklade systemet. Slutsatsen av arbetet i denna uppsats är att det är troligt att det blir billigare för museum att köpa denna typ av system ifall de utvecklas utifrån deras specifika behov jämfört med tillgängliga system på marknaden.

Off-label use of traditional Oropharyngeal Airway (OPA) as a bite-block, and the subsequential procedure of force exertion of the device by physician has caused many cases of patient’s teeth damage and monetary loss, as the patient’s incisors were damaged while clenching on the OPA during an adverse scenario called “Emergency Clenching”. To remedy this harmful situation, Bardo OPA was developed by Dr. Theodore Burdumy. The Bardo airway has unique design to transfer the clenching force from incisor to the molar. However, the Bardo OPA is one-sized, and cannot fit most of the patients like the commonly-used OPAs, such as the Berman and Gudel OPA, which have a spectrum of sizes to ensure fit. In this project, a Computer Assisted Design (CAD) simulation platform was developed to simulate the scenario where OPA is placed in a patient’s oral cavity. CAD – related technique and tools, such as 3D scanner (ScanStudio HD), RapidWorks, SolidWorks and Mimics were utilized to create the models used to construct the platform. The purpose of this platform is to generate data to support the development of additional sizes and other modification to improve the current design of the Bardo OPA. MRI sets of nine (9) patients were obtained and converted into STL mesh models. Berman and Guedel OPA were used as the standard for comparison against the Bardo OPA. It was found that the Bardo OPA was able to fit into all sample patients’ models, while these models were fitted with Berman and Guedel OPA of 70-90mm (Small to medium adult) sizes. It can only be concluded that the Bardo is compatible with these OPA sizes and there was not enough evidence to show the need for additional sizes. Nevertheless, some functional features of the Bardo OPA were found potentially harmful to the patients or ineffective. Three approaches were suggested to improve the design of the Bardo to achieve better safety and efficacy.

<p>Digitizing objects and environments from real world has become an important part of creating realistic computer graphics. Through the use of structured lighting and laser time-of-flight measurements the capturing of geometric models is now a common process. The result are visualizations where viewers gain new possibilities for both visual and intellectual experiences. </p><p>This thesis presents the reconstruction of the Parthenon temple and its environment in Athens, Greece by using a 3D laser-scanning technique. </p><p>In order to reconstruct a realistic model using 3D scanning techniques there are various phases in which the acquired datasets have to be processed. The data has to be organized, registered and integrated in addition to pre and post processing. This thesis describes the development of a suitable and efficient data processing pipeline for the given data. </p><p>The approach differs from previous scanning projects considering digitizing this large scale object at very high resolution. In particular the issue managing and processing huge datasets is described. </p><p>Finally, the processing of the datasets in the different phases and the resulting 3D model of the Parthenon is presented and evaluated.</p>