Dimensional Measurement Blog

California State University, Fullerton's SAE (Society of Engineers) Baja is off to the races with a brand new car to dominate the rugged terrain of this year's International competition track in Oregon. Engineering students from CSUF are not only faced with the task of designing and building a "single-seat, all-terrain sporting vehicle that is to be a prototype for a reliable maintainable, ergonomic, and economic production vehicle that serves the recreational user market," but they must do so while also balancing their daily classes, and for some, their jobs as well. Given such a limited amount of time to build a winning vehicle, there is even less room to spend correcting any build errors. Therefore, quality must be built into each vehicle that the SAE Baja Team designs and manufactures, and Q-PLUS Labs provides them the measurement data they need to confidently drive to victory.

Introduction

Every year, a new team assembles for this legacy project where current class seniors pass on their knowledge to upcoming juniors who will in turn pass that knowledge to their lower classmen. This through the process of raising funds to acquire the components to build the vehicle to "exposure with recruiters from leading companies in the mobility industry to help land their first engineering job after graduation." Each car starts from a design concept that has been modified over the past years of competition, however each new competition requires a new car to be built from the ground up. With each competition, the students face the time consuming and challenging process of designing the car, building the chassis, welding, and various test runs.

Our Process

The team's model this year is named after the mascot of California State University, Fullerton – Tuffy the Titan. The overall design for chassis is consistent with the team's past models, however the significant change this year will be the design of the gearbox. Unlike the previous models, this year's model features a smaller gearbox which consequently decreases the length from the input to the output shaft. This will also push the firewall further back and allow more leg room for the driver, which is important when driving on challenging terrain during the competition's four hour endurance course. CSUF's Baja Team approached Q-PLUS Labs to obtain measurement data for their chassis design. Using a FARO arm, Q-PLUS Labs was able to articulate the probe between the areas of the chassis to collect data on the car's body. Accurate measurements will help enable CSUF to confidently move forward with manufacturing the components dependent on these measurements, ensuring that their time is focused on the success of the California State University, Fullerton's SAE Baja team in their race this on May 30th-June 2nd.

Always looking for an interesting way to convey our holiday greeting, Q-PLUS Labs took on a unique approach to sharing holiday cheer with customers with a 3D scan of a Santa statue.

Our Process

To scan Santa, our engineers used the FARO Edge ScanArm HD which rapidly delivers point clouds with extreme resolution and high accuracy, even across different textures, including highly reflective surfaces. The scan data was then sent to Geomagic Design X, a poweful point cloud processing software for post processing, where it was quickly formed into a mesh and exported as a standard STL file.

The 3D file produced was a one layer, watertight mesh which was then separated into color regions. These color regions allow the mesh to be easily cut into multiple layers which were then imported into SpaceClaim to assign each individual layer its own color in context of the original Santa statue.

To render a 3D photorealistic version of the file, these colored layers into Keyshot, a program that has the ability to process and render the file in actual time. This software creates incredible visuals with 3D data and was able to produce the animations of the final rendered Santa.

California State University, Fullerton’s Titan Baja SAE (Society of Automotive Engineers) team sought Q-PLUS Labs’ measurement expertise to assist in jump starting the team’s 2015 season since their 2008 competition hiatus. Originating in 1976 at the University of South Carolina, the objective of this comprehensive engineering competition is for students to function as a team to not only design, build, test, promote, and race a vehicle, but also raise financial support while balancing the demands of their course work. To produce a formidable competitor at the 2015 Baja SAE race, the final single-seat, all-terrain sporting vehicle comprised of parts machined by CSUF’s Baja team from scrap, over the course of 9 months.

Introduction

Before building their vehicle, CSUF's Baja team designed a virtual rendering of it in Solidworks, a 3D CAD design software. Because each piece of the car was hand machined, the team needed accurate measurements of the car’s calipers before proceeding with the build. Calipers are essential to the vehicle’s ability to stop and are one of the critical components of a car’s breaks. The challenging track consisted of rough terrain, making the measurements extremely vital to vehicle’s ability to successfully navigate the race.

Our Process

Due to its complex geometry, the calipers posed a challenge for the team to model quickly. Using Q-PLUS Labs’ 3D scanning services, the team was able to “test fit” the calipers on the solid model before it was even made. Using the FARO Edge ScanArm HD, a 3D laser scanner which rapidly collects high accuracy point cloud data, Q-PLUS Labs was able to provide the team the measurement data they needed despite the reflective surface of the calipers. The scanning information that Q-PLUS Labs provided the team reduced the amount of time it would have taken them to machine the vehicle’s parts to fit the calipers.

Defying the odds of the Baja SAE race where cars were breaking down along the grueling track, CSUF’s Titan Baja team finished the race with 11 laps. Forging ahead and looking to be in the top 20 finishing teams, they are not wasting any time preparing for 2016’s race in Gorman, California on May 19^th-22^nd.

The University of California, San Diego requested Q-PLUS Labs for a unique onsite 3D scanning project of the Something Pacific installation for the Stuart Collection. This installation by Nam June Paik consists of two parts, an indoor exhibit found in the lobby of the university's Media Center as well as 3 statues of tiny Buddhas staring at dead TV sets embedded throughout the landscape UCSD's Communications/Media Center building. The resulting scans will be used to reproduce the Buddha statues in detail should they be damaged or stolen.

Introduction

Nam June Paik designed this installation which is composed of televisions paired with Buddhas watching them to depict extended contemplation. As an integral aspect of UCSD's landscape, the university sought to preserve the statues via 3D scan data in case the statues would need to be recreated in detail. For this particular application, Q-PLUS Labs' engineers used white light and laser scanning technology, specifically the Steinbichler COMET L3D and the Faro Edge ScanArm HD.

Our Process

Even with high tech 3D scanning equipment, obtaining accurate and detailed scans in an outdoor and uncontrolled environment was a meticulous process. Because the statues were unmovable and anchored into the ground, the engineers established a controlled scan environment by carefully tenting each statue to block excessive lighting.

Being in an outdoor environment, the statues required thorough and careful cleaning as well as a trench dug around each statue to render more of the statues' surface area for greater scan detail. The freeform and unusual geometry of each statue also provided a challenge to obtain scan details. However, Q-PLUS Labs' engineers completed the job and the scan data produced will help to preserve this interesting exhibit for years to come.

Lockheed Martin required Q-PLUS Labs' measurement expertise to generate quick results via 3D scan data of the rear doors of the USS Freedom in San Diego, California. As a new breed of warship, the littoral combat ship (LCS) was designed to be a fast and formidable surface combatant with warfighting capabilities such as mine clearing, anti-submarine and anti-surface warfare.

Introduction

At 378 feet in length and composed of a high speed, semi-planing steel monohull with an aluminum superstructure, the USS Freedom is a unique ship. It is the first-in-class littoral combat ship of its kind and is able to operate in a variety of environments and assignments from dangerous shallow water and near shore missions to minesweeping and humanitarian relief.

Our Process

Q-PLUS Labs went onsite with portable measurement equipment, using a range scanner to collect massive amounts of data in a highly time sensitive assignment, then post process it into the needed readings and analyses. Collecting data with the Faro Photon range scanner, which is capable of measuring roughly the length of a football field in every direction, Q-PLUS Labs' engineers were able to overcome the scanning obstacles involved with measuring onboard a currently active warship. One of the challenges in the scanning process was collecting scan data of exterior doors which involved attaching a harness an engineer as he maneuvered the equipment overboard.

In order to quickly move the USS Freedom out of port, Q-PLUS Labs was required to acquire the data rapidly and accurately, delivering results which would be used to improve the design of the ship's rear doors. These doors are located near waterline level to allow safe launch and recovery of watercrafts while the ship is in motion. The accuracy of the doors' measurements would allow for improved design to resolve the problems being caused by the shape and position of the currently installed doors.  

Case Study Update (11/19/15): Q-PLUS Labs is completing a very special and unique 3D scanning project on the USS Freedom's sister ship, the USS Independence! Look for the upcoming case study.

Dimensional inspection includes many types of scanning devices for a broad range of applications. In the realm of 3D Scanning, the level of detail that can be captured makes it the method of choice, especially for measuring very small objects requiring non-contact measurement methods.

Whereas contact 3D scanners collect measurement data by physically scanning the object with a device that comes into contact with every point on the surface, non-contact 3D Scanners collect immense amounts of data quickly without altering the geometry of the object. This is also an advantage for collecting measurements on the nano scale.

3 Types of Non-Contact 3D Scanning Methods

Laser-Scanning Confocal Microscopes
A confocal microscope uses a process called optical sectioning to collect images from various depths. These images can be reconstructed with a computer to create a 3D model of complex small objects. Unlike other laser systems, a confocal microscope only sees one depth level at a time, which allows it to generate a highly controlled depth of focus for very small objects with tight tolerances.

White Light Interferometry
This non-contact measurement system allows you to obtain surface measurements at the nanometer level. The technology behind white light interferometry uses wave superposition to measure distances based on data collected about reflected wave interactions. Interferometers can also be combined with microscopes to measure very small objects. Because they rely on the detection of waves and not optical images, interferometers are also useful for measuring objects with reflective surfaces.

Chromatic Confocal
Like interferometry, chromatic confocal also uses white light to collect measurement data. However, whereas interferometry uses the superposition of waves after they are reflected off the object, chromatic confocal measures the wavelength as it hits the surface of the object. This method produces more reliable results when measuring surface roughness or step-height depth, due to the minimum mathematical calculation required. The tolerances of large objects may allow the use of a thin whitening spray to facilitate scanning but the geometry of very small objects could be potentially buried by it. Fortunately, all of these methods work well with various types of surfaces from reflective to absorbent.

If you require any of these types of 3D Scanning methods, or if you're not sure what you need, the experts at Q-PLUS Labs are here to help. We'll work closely with you through every step of the process to ensure that you get the best results for your application. Contact us anytime if you have questions, or if you're ready to get started, call us today.

California State University, Fullerton's Society of Automotive Engineers (SAE) chapter chose Q-PLUS Labs to aid them with the challenge to compete in the Formula SAE, a competition which encompasses designing, building, and competing a mini-formula style race car that will be evaluated for its potential as a production item.

Introduction

Fullerton's SAE uses a Yamaha R6 Motorcycle engine, a large displacement choice for the 610cc class. The car's design utilizes the R6 engine as a stressed member to connect the drivetrain to the cockpit. This type of engine design requires the chassis to work with the engine as an active structural element of the chassis to transmit forces and torques, rather than using standard anti-vibration mounts to passively contain it. The R6 engine was chosen based off its high power output and ability to be used as a stressed member. In conjunction with suspension design and tire selection, the engine weight works well to keel the tires while heated under the track's conditions.

Our Process

Because the race car's design is based on the integrity and precision accuracy of the engine's measurements, Fullerton's SAE sought the expertise of Q-PLUS Labs' dimensional inspection engineers. Using a Faro Arm CMM, Q-PLUS Labs provided a dimensional analysis of each mounting point for the engine. These points are integral not only to the race car's design but also to the safety of the driver.

Given the engine's exact 3D measurements, Fullerton's SAE could confidently proceed with their design. They were able to retrofit and reverse engineer the chassis to properly fit onto the race car's engine. Currently in the manufacturing stage process, in a few months they will produce the assembled chassis to compete in the Formula SAE® Lincoln this June.