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Augmented Reality based Factory Model Comparison Method

Augmented Reality based Factory Model Comparison Method
Augmented Reality based Factory Model Comparison Method

Abstract- Through factory digital mock-up, Digital Factory (DF) technology can save enormous time and cost in factory planning. A problem of the digital factory mock-up maintenance is checking the digital models with the real factory. This paper introduces a method using Augmented Reality (AR) technology to compare the 3D models with the real object in real time. Compared to other measures, this method have the benefit of the cost saving. An experiment demonstrates the proposed method is given at the end of the paper.

Keywords-digital factory mock-up, model comparison, Augmented Reality, ARToolKit

I. INTRODUCTION

The factory digital mock-up creates a visual simulation platform for product design and processes planning which has been the key point to optimize processes and offer optimal production scheme [1]. It works as the foundation of Digital Factory (DF) technology which is widely used in many fields such as aviation, automobile manufacturing, chemical industry and electronic products. Model calibration is a significant issue in the application of factory digital mock-up. Previous methods of model comparison perform inefficient and high-cost, which result in a deep impact on the development of DF. With the expectation of seeking a cost-effective way, Augmented Reality (AR) is proposed to be used in factory digital model comparison [2, 3].

II. FACTORY DIGITAL MOCK-UP Factory digital mock-up is a complex of digital archive for the whole life-cycle of a factory. It includes not only 3D model of the factory, but also all the design documents, construction documents, and maintenance information. DF technology, the company to meet the challenges of the 21st century an effective means [4], which integrates techniques of computer, virtualization, emulation, and networks, plays a significant role in keeping competitive advantage for enterprises. It operates in a collaborative way under 3-D visualization environment and interactive interface. Based on the actual data and models the planned products and production processes can be improved using virtual models until the processes are fully developed and extensively tested for their use in the real factory. DF is a comprehensive approach in factory layout planning, which consists of the 3-D model design of plant (that contains workshop structure, equipments and facilities, material flow and other resources for production) and processes optimization[5]. And Factory digital mock-up acts as the prerequisite for operative information concerned.

Factory digital mock-up shows its advantages: engineers make assessment by optimizing the plant layout and resolving conflicts between different parts, then avoid loss due to irrational design, and make data and information of equipments and process flow optimum coordinate with the factory building [6]. When applied in the aspect of automobile industry, it coordinates materials resource (components and modules of automobile), equipment (machine tools and facilities), workshop (area), and process flow (automobile manufacturing processes) into an IT system. While in the field of pharmaceutical and chemical industry, factory digital mock-up makes it possible to increase product innovation and flexibility.

III. METHODOLOGY

A. Method of factory digital mock-up comparison

One of the most basic problems currently limiting factory digital mock-up applications is updating. Regular calibrating factory models taking real factory for reference is necessary. There are several model comparison methods prevailed: laser scanning, laser ranging, photograph-visual inspection comparison.

Laser scanner firstly gets the outline integrated data of the object rapidly by Omni-directional scanning, and then generates point cloud records after precisely construction, editing, and modification by computer. Accurate as the data is, the method cannot be widely used because of the high cost. Furthermore, the instrument is unable to display data instantly.

Another approach for updating factory digital mock-up is laser ranging. People can easily obtain elevation and other information of the object, relative position, for example, using the hand-held laser distance meter. However, this kind of method is not appropriate for objects which are precise and complicated.

Photograph-visual inspection means to make a comparison between real factory and the photograph of the factory. It is feasible, however, not accurate.

Augmented Reality based Factory Model Comparison Method

Jian-feng LU1,a, Wei-wei SUN1,b, De-zhong LI2,c

1CIMS Research Center, Tongji University, Shanghai, China

2CDHAW, Tongji University, Shanghai, China

(a lujianfeng@https://www.doczj.com/doc/a115852018.html, , b sunweiweid@https://www.doczj.com/doc/a115852018.html, , c dezhonglee@https://www.doczj.com/doc/a115852018.html,)

These methods above are commonly used at present. However, more efforts should be paid to explore new resort which is inexpensive and accurate. Therefore, Augmented Reality based factory model comparison method has been proposed. AR system can present a view of blended scene of real factory environment and digital mock-up. Then the information files can be easily changed to correct the model without complicated manual operation.

B. Augmented Reality and ARToolKit

Augmented Reality (AR) technology can enhance user’s perception of the real world by providing information from computer system. It has the following three characteristics: combine real and virtual, interactive in real time, and registered in 3-D [7, 8]. AR system has been applied in medical, manufacturing, visualization, path planning, entertainment, military and many other aspect [9].

ARToolKit is an AR application development tool kit based on C/C++ language. It has successfully developed indoor registration technology with fiducial mark pattern tracking system. On the condition of controlled environment, it has achieved a fine tracking result. The kit includes camera calibration and mark making tool which can compound Direct3D, OpenGL graphics and VRML scenes into the video stream and support a variety of display devices.

C. Augmented Reality based factory model comparison method

Figure1. AR based model comparison method work process

Augmented Reality based factory model comparison method is put forward on the foundation of model-loaded procedure in ARToolKit to blend virtual objects seamlessly with a real factory environment in 3-D. The mainly work flow is shown in Figure 1.

Figure2. The real object scanning

Take the case of a section of a cross fire fighting sprinkler and a pipe support in a classroom (as Figure 2 shows) which is too high to measure, just meet the requirements of the experiment object selection.

The operating system is Windows XP with Microsoft Visual studio 2008 development environment. An ordinary CMOS camera (pixels 320×240) with 2.0 USB interface and a printed fiducial mark is enough.

Besides provided mark patterns, other patterns also can be designed and trained according with the instruction in ARToolKit. There are some limitations to purely computer vision based AR systems. The larger the physical pattern, the further away the pattern can be detected. What’s more, the simple pattern is better. Taking the height of experimental subject into account, a proper coordinate axis offset should be set to get a clearly vision. The mark was fixed in the bottom right-hand corner of the object which is also shown in Figure 2.

DAT files contain the name, size display, rotation and other information of the models. Some new models can be matched with modifying the data as well as model updating. When multiple patterns tracked associate with different 3D object needed, DAT files also can be easily fixed to load more than one pattern.

Figure3. The initial vision of blending

The virtual model of the classroom was created by Microstation in real proportion and converted into WRL by 3DSMAX. The mark shown in Figure 2 has been

trained to match the digital model. The initial vision of the blending scene was rendered as soon as the camera

identified the mark, which is shown in Figure 3.

The model and the vision of real object can be rotated synchronously when the camera moved. While immersed in a view of real world, some subtle changes in DAT files can make the model get closer to the object. Then the position can be determined with acceptable precision and accuracy in real time. The modified model was shown in Figure 4.

Figure4. The modified vision of blending

V. CONCLUSION AND FUTURE WORK

From the conclusions drawn from experiment above, Augmented Reality based factory model comparison method has the following advantages over the existing methods:

(1). Flexibility. The method operated in a direct way which has avoided laser scanning, ranging, or other manual work.

(2). Low-cost. It can do the work well without professional instrument and also result in time-saving.

(3). Accuracy. The real object was blended with the virtual model seamlessly, that lead to errorless result.

(4). Real-time. The real world and the digital model were rendered and combined in real time, and it is possible to reduce time with the use of the method by working more efficiently.

Certainly, there are also some limitations. The method cannot work without document database of the object, while Laser scanning is better. And Laser ranging does well in presenting data like elevation and relative position for some big facilities. It is more efficiently to make a proper combination of these approaches in the real factory.

Since visual interface has advanced the performance, more effort needed to perfect the AR system, which includes tracking visible natural features without prepared marks [10], model loaded automatically, project of the controller interface with CAD and so on. The author will do further study in this area to support the factory digital modeling techniques in future.

R EFERENCES

[1] U. Bracht, T.Masurat. The digital factory between vision

and reality [J]. Computers in Industry, 2005,56(4): 325-333.

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[3] AZUMA R T, BAILLOT Y,BEHRINGER R,et al,Recent

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[4] Liu Duangui. About Digital Factory [DB/OL].

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application of Digital Factory (Chinese) [M]. Beijing: China Machine Press, 2006: 28-29

[6] Yu Chenglong, Guo Gang, Liu Jiabao. “Digital Mock-up

(DMU) technology in the development of product innovation”. Sichuan Ordnance Journal, 2003,pp. 45-48 [7] Ronald T. Azuma. A Survey of Augmented Reality [J].

Presence: Teleoperators and Virtual Environments , 1997, 6(4): 355–385.

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Feiner, Simon Julier, and Blair MacIntyre. Recent advances in Augmented Reality [J]. IEEE Computer Graphics and Applications, 2001, 21(6): 34~47.

[9] Quan Hongyan, Wang Changbo, Ling junjun.“Survey of

vision-based augmented reality technologies”. Robot, 2008, pp.379-384.

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