Measurement Solutions Limited - Leaders in 3D Measuring Systems and SPC Solutions

Aicon : Special Applications

As one of the World's leading developers of 3D measuring system based on digital camera technology, Aicon have been tasked on many occasions with providing specific solutions for individual customer requirements, especially in the areas of vehicle testing. Very often, these bespoke solutions can be modified for use on a variety of measuring applications. Here we show just a few examples of specialist applications and solutions.

DuPos : Crash Test Dummy Positioning

In new car development, crash and sled tests are conducted in order to minimize the passengers’ risk of injury. In order to receive necessary approvals, car manufacturers have to respect a multitude of standards and regulations so they can assure optimal levels of safety.

The DuPos system consists of four high resolution digital cameras, a portable PC for system control, a wireless probe, accessories to target the points on the dummy, and the DuPos software. The synchronised cameras capture 3D object points at a frequency of up to 5Hz. The target points are fixed on the dummy, the test vehicle or on target point adapters. The DuPos software is specially developed for the purpose of dummy positioning. Combined with the DuPos system, the optical 3D positioning system controls the 3D position of the dummy relative to the vehicle during the positioning process. The current dummy position is recorded in real time compared to nominal data, and the differences between the target positions and reference positions are displayed graphically or numerically. With all points on the dummy measured and displayed simultaneously in vehicle coordinates, the technician can quickly put the dummy into its target position. Movements of the vehicle that are caused by the positioning of the dummy are compensated automatically because of continuous monitoring of a set of targeted reference points.

Using AICON’s DuPos system for dummy positioning, the user can conduct a complete positioning including preparation and additional measurements within a few minutes. The portability of the system makes it applicable for dummy positioning both in vehicles for crash barrier and on bucks for sled tests.

ProCAM : Fast and Easy Crash Vehicle Measurement

The mobile probe ProCam consists of an active probe with a high resolution CCD camera, a portable PC for system control and the software module ProCam Crash. During the measurement, the camera is held facing a field of control points that is located nearby, either on portable or on fixed panels. The operator places the ruby ball tip in contact with the feature being measured, an pushing a button on the probe the 3D coordinate location is immediately calculated. ProCam Crash is a software module that has been specially designed for the measurement of vehicle geometries before and after crash tests. It guides the user through the measurements in an intuitive way. The software can be learned easily and uses integrated functions to optimise the measuring procedure. The user is able to define the details of the measuring procedure before the measurement starts.

First, the software calculates the alignment of the vehicle with an arbitrary number of points defined by various types of features (slot, circle, plane, etc.). Thanks to overview pictures, the user immediately knows the position of a measuring point on the vehicle. The measured points are highlighted permitting the user to follow the progress of the measurement. The measuring points of the pre-crash measurement are stored in a data file together with all information relevant to the test. The user can re-apply this file for the post-crash measurement.
During the post crash measurement, the same points are touched a second time; they are recorded in the same coordinate system and directly compared to the results of the pre-crash measurement. The existing deformation between the points is determined automatically and can be documented and visualised with the help of user specific reports.

WheelWatch : High Speed Monitoring of Wheel Motion

WheelWatch consists of a high-resolution high-speed digital camera with an integrated high performance flash and image analysis processor. The integrated high-speed digital camera features extremely short shutter speeds of just a few microseconds that are necessary for long duration tests. The high quality camera also ensures the system is robust and stable over time.
The system provides data at a frequency of 490Hz, ideal for studying and optimizing static and dynamic chassis parameters. Measurements are controlled automatically and may be collected over long periods of time. The triggering function ensures that multiple sensors are fully synchronized.
The camera, which can be mounted at a distance of less than 500mm (20 in) from the fender, uses TCP/IP protocol to communicate with the laptop computer which controls the system, located in the test vehicle. The vehicle 12 Volt power system provides power during the test drive. WheelWatch can measure wheel movements for a vehicle travelling at speeds of up to 250km per hour (160mph). The system is also capable of observing extreme driving manoeuvres. Points are measured to an accuracy of about ±0.1mm (0.004 in) and angles to an accuracy of about ±0.015°.

EngineWatch : 6D Measurement of Engine Movements

In vehicle development, exact information about engine-to-body clearance is necessary to ensure an optimal design of the available space. For example, the engine must not collide with other parts in the engine bay when the driver changes gears or deals with difficult driving manoeuvres. AICON’s optical measuring system EngineWatch is now available to measure engine movements precisely.

The system acquires engine movements in six degrees of freedom (6-DOF), both during a test drive and in a test station. Thus it replaces traditional devices such as mechanical travel sensors. The position and orientation of the measured points is depicted with absolute values in the vehicle coordinate system. At the same time, it is also possible to monitor movements of other relevant parts in the engine bay, for example movements of the battery box. The optical measuring system EngineWatch works on a non-contact base i.e. without a mechanical connection between sensor and engine block. Therefore, EngineWatch delivers reliable measuring results, also under extreme dynamic conditions. The measuring frequency goes up to 490Hz, and unlike traditional systems measuring data can be recorded for an unlimited period of time.