Propeller Blade Measurement Using Structured Light 3D Camera
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Solution Overview
Problem
Traditional methods for propeller detection are inefficient, labor-intensive, and prone to errors due to manual measurement and the high cost and complexity of three-coordinate measuring machines, which affect the reliability and accuracy of propeller blade measurements.
Innovation Solution
A high-precision structured light 3D camera-based method using the open-source PCL framework to obtain and process point clouds, filter out stray points, determine measurement planes, and calculate propeller parameters such as blade height and pitch, enabling efficient and accurate propeller qualification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement with calipers is used, then the detection method is simple and equipment cost is low, but the measurement precision and detection efficiency deteriorate due to human error and time-consuming processes
Solution Approach 1:
The patent replaces manual mechanical measurement with calipers with an automated optical measurement system using structured light 3D cameras. The system captures point cloud data of the propeller blades and uses computer vision algorithms to automatically extract geometric parameters, eliminating human error and significantly improving measurement precision while maintaining reasonable equipment complexity through the use of commercial off-the-shelf cameras and open-source processing software.
Solution Approach 2:
The patent creates a digital copy of the physical propeller blade by capturing its three-dimensional point cloud data using structured light projection. This digital model is then processed to extract blade parameters such as pitch, diameter, and airfoil geometry, allowing for non-contact, high-precision measurement that preserves the original blade while enabling repeated analysis.
2Measurement precision
If a three-coordinate measuring machine is used, then the measurement precision improves, but the equipment cost, device complexity, and space requirements worsen
Solution Approach 1:
The patent replaces the complex mechanical three-coordinate measuring machine with an optical-based structured light system. Instead of using physical probes that require precise mechanical positioning, the system projects structured light patterns onto the blade surface and uses cameras to capture the deformed light patterns, converting mechanical measurement problems into optical and computational problems that can be solved with more compact and cost-effective equipment.
Solution Approach 2:
The patent introduces structured light patterns as an intermediary between the measurement system and the blade surface. These projected light patterns serve as a reference framework that enables the camera to accurately measure three-dimensional geometry without direct physical contact, replacing the complex mechanical probe system with a simpler optical intermediary that bridges the gap between the camera and the measurement target.
3Productivity
If manual measurement methods are used, then the equipment cost is low, but the detection efficiency and productivity worsen due to labor-intensive processes
Solution Approach 1:
The patent implements a self-service measurement system where the structured light camera automatically captures point cloud data, and the embedded processing algorithms autonomously extract blade parameters without requiring manual intervention. The system performs self-calibration, automatic feature recognition, and parameter calculation, eliminating the need for operators to manually measure and record data, thereby dramatically improving detection efficiency and reducing labor input.
Solution Approach 2:
The patent enables continuous measurement and processing operations by implementing an automated workflow where the structured light camera continuously captures blade geometry data, and the processing system continuously analyzes the point cloud to extract parameters. This continuous operation eliminates the intermittent, step-by-step nature of manual measurement, allowing for rapid sequential measurement of multiple blades and significantly boosting overall detection productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution improves detection efficiency and accuracy, reducing labor costs and equipment complexity while ensuring high-precision propeller measurement, enhancing the feasibility of propeller quality control.
Implementation Method 1
detect the propeller by means of a structured light 3D camera and obtain the measurement point cloud of the propeller
Data Source
AI summary
A method and device for detecting propellers with high-precision are provided, the method includes obtaining a measurement point cloud of the propeller, filtering the measurement point cloud to obtain a target point cloud; processing the target point cloud to obtain a first measurement plane, and finding a center point of a pressure cone point cloud; obtaining a measuring axis according to the first measurement plane and the center point; segmenting the target point cloud to obtain a blade point cloud of each blade, and analyzing the blade point cloud and the measuring axis to obtain the parameters of the propeller, so as to determine whether the propeller is qualified. A high-precision structured light 3D camera is used, simple and high-precision detection solution for propeller products is developed based on the open-source 3D algorithm framework PCL. The device can improve the detection efficiency and the feasibility of promotion.