基于激光360度回转测量和Pro/Scan-Tools的集成逆向工程系统研究
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摘要
传统的产品开发流程的预定顺序是按照概念设计、详细设计、制定工艺流程、设计工装夹具、加工及装配进行的。但现代生产中，如某些流线型物体、人体假肢、艺术雕塑品和汽车零件产品，其原始模型并非来自设计概念而是实物产品。逆向工程(Reverse Engineering，RE)CAD／CAM系统与传统的设计制造过程不同，该系统首先利用先进测量方法对实物进行三维数字化处理，借助专用的曲面重构软件及CAD系统反求出实物的CAD模型，然后再按照传统的制造流程生产出产品或原型。RE技术通常涉及三维测量(表面数字化)、数据处理、曲面重构、三维建模及快速制造等相关技术。逆向工程CAD／CAM系统具有广泛的工业用途，其研究开发工作具有较大的理论意义和应用价值。
本文工作源于世界银行贷款的中国高等教育改革项目，利用该项目的设备，以RE技术在制造业的应用为背景，研究有机集成激光三维测量、CAD／CAM系统、快速原型制造和数控加工设备为一体的集成化逆向工程(Integrated Reverse Engineering，IRE)系统及其关键技术。文中对比分析了目前主要的技术方案，提出了一种非常方便而实用的IRE系统模型，即基于激光360度回转测量及Pro／Scan-tools的IRE系统模型。该系统主要包括四个子系统：数据采集及处理系统、曲面重构系统、三维建模系统及CAM子系统，具有两个接口：曲面重构数据输入输出接口、制造系统数据输入输出接口。实践证明该系统模型较为先进，能用于工业用途。现已将部分模块成功用于四川大学工程培训中心的学生逆向工程实验。
本文的主要理论研究与系统研制开发工作包括：
论文摘要
l)深入研究了自由曲面的测量方法及其测量策略，着重分析了激光三维数
字化技术，并将其用于实际的IRE系统。同时，文中对几种基本的测量数据预
处理方法进行了分析。
2)本文对基于Pro/Scan一too1s的曲面重构方法进行了研究，在对比现有
方案的基础上，总结出了一套利用现有软件，由点云数据直接重构出自由曲面
模型的方法，并将其用于实际的工RE系统。同时，本文还对以边界为中心的曲
面重构方法及利用人工神经网络技术的自由曲面重构技术进行了研究。
3)本文在对RE过程中的关键技术进行深入分析和研究的基础上，利用现
代最新的科学知识和本领域及其它学科的研究成果，互相结合，交叉渗透，对
文中提出的工RE系统进行了实际的开发与集成。在对系统的各关键模块研究的
同时，本文使用VC+十6.0设计开发了相关的数据接口程序，将系统中的各个模
块有机地结合成一个整体。使反求过程得以顺利地实现。
The traditional product developing process is an ordinal model, viz., begin with conception design, and then produce it out according to the drawing. In many situations, however, product is not come from designed conception but from some other entities, and it must be produced without any existing drawing, such as sculpture. Being different against the traditional process of design and manufacture, in the reverse engineering (RE) CAD/CAM system, we must use advanced measuring methods to make the entity digitalized first, then reconstruct the CAD module of the entity using special surface reconstruction software and CAD system, at last produce the final product or prototype according to the traditional produce process. The RE technique is generally composed of 3-D surface digitalization, data procession, surface reconstruction, CAD 3-D modeling and rapid manufacture, etc. The reverse engineering CAD/CAM system has broad industrial usage, and the research work has extremely theoretic and application importance.
The task of this paper roots in the Chinese higher education reform item of the World Bank loan project. Using the equipment of this item, and regarding the RE's application in industry as the background, the paper researched the integrated reverse engineering (IRE) and its pivotal technology, which has integrated laser 3-D measurement, CAD/CAM system, and rapid prototype (RP) manufacture. The paper contrasted and analyzed main scheme at present, and brought forward a co-
and applied IRE system model, viz., the IRE system based on the 360?rotating laser measurement and Pro/Scan-tools. The system mainly includes four subsystems: data collection and procession, surface reconstruction, 3-D modeling and CAM system; two interfaces: the data in-out interfaces for surface reconstruction and manufacture system. It's been proved by the practice that this system is advanced and could been used in industry. Partial module of this IRE system now has been used successfully in the students' reverse engineering experiments for the engineering training center of Sichuan university.
The theoretics and development pursuit of this paper include the following items.
1. The paper deeply researched the freeform-surface inspecting methods and the inspecting strategy, especially the 3-D laser digitalization technique, and applied it into the actual IRE system; Meanwhile this paper analyzed several basic techniques of data procession.
2. The paper researched reconstruction method based on the Pro/Scan-tools, and summed up a complete way of reconstructing freeform-surface model from "point cloud" data using existing software; meanwhile this paper researched the reconstruction theory based on the technique of ANN.
3. Basing on the deep analyses and researching in the pivotal technologies of RE process, and utilizing the fruit of several engineering fields, this paper exploited and integrated the IRE system that is brought forward by the paper itself. This paper researched the key modules of the system, used the VC++6.0 to develop the related interface program, and integrated every module into an organic integer. At last, it realized the reverse process successfully.
本文工作源于世界银行贷款的中国高等教育改革项目，利用该项目的设备，以RE技术在制造业的应用为背景，研究有机集成激光三维测量、CAD／CAM系统、快速原型制造和数控加工设备为一体的集成化逆向工程(Integrated Reverse Engineering，IRE)系统及其关键技术。文中对比分析了目前主要的技术方案，提出了一种非常方便而实用的IRE系统模型，即基于激光360度回转测量及Pro／Scan-tools的IRE系统模型。该系统主要包括四个子系统：数据采集及处理系统、曲面重构系统、三维建模系统及CAM子系统，具有两个接口：曲面重构数据输入输出接口、制造系统数据输入输出接口。实践证明该系统模型较为先进，能用于工业用途。现已将部分模块成功用于四川大学工程培训中心的学生逆向工程实验。
本文的主要理论研究与系统研制开发工作包括：
论文摘要
l)深入研究了自由曲面的测量方法及其测量策略，着重分析了激光三维数
字化技术，并将其用于实际的IRE系统。同时，文中对几种基本的测量数据预
处理方法进行了分析。
2)本文对基于Pro/Scan一too1s的曲面重构方法进行了研究，在对比现有
方案的基础上，总结出了一套利用现有软件，由点云数据直接重构出自由曲面
模型的方法，并将其用于实际的工RE系统。同时，本文还对以边界为中心的曲
面重构方法及利用人工神经网络技术的自由曲面重构技术进行了研究。
3)本文在对RE过程中的关键技术进行深入分析和研究的基础上，利用现
代最新的科学知识和本领域及其它学科的研究成果，互相结合，交叉渗透，对
文中提出的工RE系统进行了实际的开发与集成。在对系统的各关键模块研究的
同时，本文使用VC+十6.0设计开发了相关的数据接口程序，将系统中的各个模
块有机地结合成一个整体。使反求过程得以顺利地实现。
The traditional product developing process is an ordinal model, viz., begin with conception design, and then produce it out according to the drawing. In many situations, however, product is not come from designed conception but from some other entities, and it must be produced without any existing drawing, such as sculpture. Being different against the traditional process of design and manufacture, in the reverse engineering (RE) CAD/CAM system, we must use advanced measuring methods to make the entity digitalized first, then reconstruct the CAD module of the entity using special surface reconstruction software and CAD system, at last produce the final product or prototype according to the traditional produce process. The RE technique is generally composed of 3-D surface digitalization, data procession, surface reconstruction, CAD 3-D modeling and rapid manufacture, etc. The reverse engineering CAD/CAM system has broad industrial usage, and the research work has extremely theoretic and application importance.
The task of this paper roots in the Chinese higher education reform item of the World Bank loan project. Using the equipment of this item, and regarding the RE's application in industry as the background, the paper researched the integrated reverse engineering (IRE) and its pivotal technology, which has integrated laser 3-D measurement, CAD/CAM system, and rapid prototype (RP) manufacture. The paper contrasted and analyzed main scheme at present, and brought forward a co-
and applied IRE system model, viz., the IRE system based on the 360?rotating laser measurement and Pro/Scan-tools. The system mainly includes four subsystems: data collection and procession, surface reconstruction, 3-D modeling and CAM system; two interfaces: the data in-out interfaces for surface reconstruction and manufacture system. It's been proved by the practice that this system is advanced and could been used in industry. Partial module of this IRE system now has been used successfully in the students' reverse engineering experiments for the engineering training center of Sichuan university.
The theoretics and development pursuit of this paper include the following items.
1. The paper deeply researched the freeform-surface inspecting methods and the inspecting strategy, especially the 3-D laser digitalization technique, and applied it into the actual IRE system; Meanwhile this paper analyzed several basic techniques of data procession.
2. The paper researched reconstruction method based on the Pro/Scan-tools, and summed up a complete way of reconstructing freeform-surface model from "point cloud" data using existing software; meanwhile this paper researched the reconstruction theory based on the technique of ANN.
3. Basing on the deep analyses and researching in the pivotal technologies of RE process, and utilizing the fruit of several engineering fields, this paper exploited and integrated the IRE system that is brought forward by the paper itself. This paper researched the key modules of the system, used the VC++6.0 to develop the related interface program, and integrated every module into an organic integer. At last, it realized the reverse process successfully.
引文
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2. Papstel Jyri,Saks Alo. Virtual manufacturing in reality. Proceedings of SPIE The International Society for Optical Engineering. 2000 (Nov 6): p123～133
3. Banerjee Amarnath. Behavioral layer architecture for telecollaborative virtual manufacturing operations. IEEE Transactions on Robotics and Automation. 2000 IEEE (Jun3): p 218～227
4．张巨香．反求工程在模具制造中的应用．机械工人，2002(11)：46-47
5．张舜德，魏正英，卢秉恒．逆向工程技术及其工业应用．甘肃工业大学学报，2001，27(2)：25—28
6. Mavromihales, M., Mason, J., Weston, W. A case of reverse engineering for the manufacture of wide chord fan blades (WCFB) used in rolls Royce aero engines. Journal of Materials Processing Technology, 2003, 134(3): 279-286
7. Fine, L., Leon, J. A reverse engineering approach for finite element model generation of historical constructions and industrial parts. Proceedings of the Third International Conference on Engineering Computational Technology, 2002, p9-10
8．李明．逆向工程的应用及其集成．机械制造．1996，(11)：4-6
9. Hon-Yue Chou, Application of reverse engineering in die and mold manufacturing, 3rd Int. Conf. on Mould & Die Technique in Asia. Taibei, China, pp753-764
10. Dipl. Ing. Thomas Haller, Rapid mould and die making using reverse engineering and rapid prototyping, 3rd Int. Conf. on Mould and Die Technique in Asia, Taibei, China, pp739-752
11. Baxter, Ira D., Mehlich, Michael. Reverse engineering is reverse forward engineering. Science of Computer Programming, 2000, 36 (2): 131-147
12. Liu, Xing-Wei, Yin, Guo-Fu, Luo, Yang. Research on reverse engineering system model based on partial surface reconstructing. Computer Integrated
Manufacturing Systems, CIMS, 2001, 4(7): 12-16
13．胡敏，扬虹，来新民等．逆向工程在汽车制造质量控制中的应用．机械设计与研究，2000，2：68-70
14．田晓东，史桂蓉，阮雪榆．复杂曲面实物的逆向工程及其关键技术．机械设计与制造工程．2000，29(4)：1-3
15．孙福辉，席平，唐荣锡．复杂产品集成逆向工程系统及其关键技术．北京航空航天大学学报．200l，27(3)：351-353
16．刑渊．集成反向工程系统及其关键技术的研究．上海交通大学博士学位论文．1998，5
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18. Chen Y H, NG C T, Wang Y Z. Generation of an STL File from 3D Measurement Data with User-controlled Data Reduction. International Journal of Advanced Manufacturing Technology, 1999, 15(2): 127-131
19．金涛，陈建良，童水光．逆向工程技术研究进展．中国机械工程．2002，16(13)：1430-1436
20. Evans, M. Robotics based part inspection and reverse engineering system. Proc. 39th Conf. Remote Systems Technology. San Francisco, CA (Nov. 1991), pp189-193
21. Kwok, W I, Eagle, P. Reverse engineering extracting CAD data from existing parts, Mechanical Eng., Vol.113, No. 3, 1991, pp52-55
22. Reverse engineering cuts revision time in half. Design News, Vol. 45, 1989, pp38
23. Robert J, Abella, James M. Daschbach. Reverse engineering industrial applications. Computers Ind. Engng., Vol. 26, No. 2, 1994, pp381-385
24. Motavalli. S, Bidanda. B. A part image reconstruction system for reverse engineering of design modifications. J. Manufacturing syst. 10(5), 1991, pp383-395
25. SHI Guirong, XING Yuan, ZHANG Yongqing. Reverse-engineering Automatic Geometry Modeling System.Journal of Shanghai Jiaotong University, 2000, 34 (3): 392-395
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27．李际军．反求工程CAD建模关键技术研究．浙江大学博士学位论文，1998
28．周儒荣，张丽艳，苏旭等．海量散乱点的曲面重建算法研究．软件学报，2001，12(2)：249-255
29．陈吉红．三维曲面视觉测量与重建技术研究．华中科技大学博士学位论文，2000
30．林奕鸿．散乱数据曲面重构技术的研究．华中科技大学博士学位论文，2000
31．曾翰通，李明，顾佳明．逆向工程应用中的技术集成及优化再设计．机械工程师，2002，7．29-31
32. Liang-Chai Chen, Grier C. Lin. Reverse engineering in the design of turbine blades-a case study in applying the MAMDP [J]. Robotics and Computer Integrated Manufacturing 2000(16): 161-167
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34．方新，费仁元．实物逆向工程的关键技术．现代制造工程．2002，(12)：18—21
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2. Papstel Jyri,Saks Alo. Virtual manufacturing in reality. Proceedings of SPIE The International Society for Optical Engineering. 2000 (Nov 6): p123～133
3. Banerjee Amarnath. Behavioral layer architecture for telecollaborative virtual manufacturing operations. IEEE Transactions on Robotics and Automation. 2000 IEEE (Jun3): p 218～227
4．张巨香．反求工程在模具制造中的应用．机械工人，2002(11)：46-47
5．张舜德，魏正英，卢秉恒．逆向工程技术及其工业应用．甘肃工业大学学报，2001，27(2)：25—28
6. Mavromihales, M., Mason, J., Weston, W. A case of reverse engineering for the manufacture of wide chord fan blades (WCFB) used in rolls Royce aero engines. Journal of Materials Processing Technology, 2003, 134(3): 279-286
7. Fine, L., Leon, J. A reverse engineering approach for finite element model generation of historical constructions and industrial parts. Proceedings of the Third International Conference on Engineering Computational Technology, 2002, p9-10
8．李明．逆向工程的应用及其集成．机械制造．1996，(11)：4-6
9. Hon-Yue Chou, Application of reverse engineering in die and mold manufacturing, 3rd Int. Conf. on Mould & Die Technique in Asia. Taibei, China, pp753-764
10. Dipl. Ing. Thomas Haller, Rapid mould and die making using reverse engineering and rapid prototyping, 3rd Int. Conf. on Mould and Die Technique in Asia, Taibei, China, pp739-752
11. Baxter, Ira D., Mehlich, Michael. Reverse engineering is reverse forward engineering. Science of Computer Programming, 2000, 36 (2): 131-147
12. Liu, Xing-Wei, Yin, Guo-Fu, Luo, Yang. Research on reverse engineering system model based on partial surface reconstructing. Computer Integrated
Manufacturing Systems, CIMS, 2001, 4(7): 12-16
13．胡敏，扬虹，来新民等．逆向工程在汽车制造质量控制中的应用．机械设计与研究，2000，2：68-70
14．田晓东，史桂蓉，阮雪榆．复杂曲面实物的逆向工程及其关键技术．机械设计与制造工程．2000，29(4)：1-3
15．孙福辉，席平，唐荣锡．复杂产品集成逆向工程系统及其关键技术．北京航空航天大学学报．200l，27(3)：351-353
16．刑渊．集成反向工程系统及其关键技术的研究．上海交通大学博士学位论文．1998，5
17. Lin A C, Liu H T. Automatic Generation of NC Cutter Path From Massive Data Points. Computer Aided Design, 1998, 30(1): 77-90
18. Chen Y H, NG C T, Wang Y Z. Generation of an STL File from 3D Measurement Data with User-controlled Data Reduction. International Journal of Advanced Manufacturing Technology, 1999, 15(2): 127-131
19．金涛，陈建良，童水光．逆向工程技术研究进展．中国机械工程．2002，16(13)：1430-1436
20. Evans, M. Robotics based part inspection and reverse engineering system. Proc. 39th Conf. Remote Systems Technology. San Francisco, CA (Nov. 1991), pp189-193
21. Kwok, W I, Eagle, P. Reverse engineering extracting CAD data from existing parts, Mechanical Eng., Vol.113, No. 3, 1991, pp52-55
22. Reverse engineering cuts revision time in half. Design News, Vol. 45, 1989, pp38
23. Robert J, Abella, James M. Daschbach. Reverse engineering industrial applications. Computers Ind. Engng., Vol. 26, No. 2, 1994, pp381-385
24. Motavalli. S, Bidanda. B. A part image reconstruction system for reverse engineering of design modifications. J. Manufacturing syst. 10(5), 1991, pp383-395
25. SHI Guirong, XING Yuan, ZHANG Yongqing. Reverse-engineering Automatic Geometry Modeling System.Journal of Shanghai Jiaotong University, 2000, 34 (3): 392-395
26．史桂蓉，刑渊，张永清．反向工程几何建模自动化系统．上海交通大学学报，2000，34(3)：392-395
27．李际军．反求工程CAD建模关键技术研究．浙江大学博士学位论文，1998
28．周儒荣，张丽艳，苏旭等．海量散乱点的曲面重建算法研究．软件学报，2001，12(2)：249-255
29．陈吉红．三维曲面视觉测量与重建技术研究．华中科技大学博士学位论文，2000
30．林奕鸿．散乱数据曲面重构技术的研究．华中科技大学博士学位论文，2000
31．曾翰通，李明，顾佳明．逆向工程应用中的技术集成及优化再设计．机械工程师，2002，7．29-31
32. Liang-Chai Chen, Grier C. Lin. Reverse engineering in the design of turbine blades-a case study in applying the MAMDP [J]. Robotics and Computer Integrated Manufacturing 2000(16): 161-167
33．雷刚，邹昌平，黄剑鸣．快速逆向工程研究进展．机械工艺师．2000，(10)：54-56
34．方新，费仁元．实物逆向工程的关键技术．现代制造工程．2002，(12)：18—21
35．李剑，鞠华，王恒奎，王文，陈子臣．自由曲面测量研究综述．计量技术．2001，(1)：8—11
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