Surface inspection system and method
A surface inspection system and method includes a mobile computing device having a processor, an optical assembly, a memory device, and interfaces in communication with the processor, the memory storing instructions that when executed cause the system to perform the operations of generating a series of images representing a surface, receiving a selection of a region of interest in the series of images, generating a virtual high-resolution 3D reconstruction of the region of interest, and determining measurement information within the region of interest.
1 . A system for inspecting a surface, the system comprising:
a mobile computing device comprising:
a processor;
an optical assembly in electronic communication with the processor;
a human-machine interface in communication with the processor, the human-machine interface comprising a display device and an input device; and
a memory device in electronic communication with the processor, the memory device storing instructions that when executed cause the mobile computing device to execute operations of:
generating, via an optical assembly, a series of images representing the surface, the series of images defining a first image data set;
generating, via the processor, a sparse 3D reconstruction of the surface based on a recognition of sparse features within the first image data set;
after generating the sparse 3D reconstruction, receiving, via the input device, a selection of a region of interest of the surface that includes a surface feature;
defining, with the processor, a second image data set, the second image data set being a subset of the first image data set and having the selected region of interest;
after receiving the selection of the region of interests, generating, with the processor, a dense 3D reconstruction of the region of interest and that includes the surface feature, the dense 3D reconstruction based on the second image data set;
generating, on the display device, a rendering of the dense 3D reconstruction; and
determining, with the processor a measurement data within the region of interest, wherein the region of interest of the surface includes the surface feature, and wherein the measurement data includes an elevation of the surface feature.
2 . The system of claim 1 , wherein the memory device further comprises instructions that when executed cause the mobile device to execute an operation of receiving, via the input device, a selection of a measurement area of the dense 3D reconstruction, and wherein the measurement data is associated with the measurement area.
3 . The system of claim 2 , further comprising generating and displaying a plot, wherein the plot illustrates the minimum or a maximum within the measurement region.
4 . The system of claim 1 , wherein generating the series of images comprises recording a video.
5 . The system of claim 1 , wherein generating the series of images comprises generating, on the display device, instructions to move the mobile computing device relative to the surface.
6 . The system of claim 5 , wherein the instructions comprise one of a translation direction, a distance direction, a rotation direction, or combinations thereof.
7 . The system of claim 1 , wherein generating the series of images comprises generating, on the display device, live feedback representing a scan quality negatively impacted by high ambient brightness, the surface being shiny, or both.
8 . The system of claim 1 , wherein the sparse 3D reconstruction comprises a virtual 3D model of between 300 and 1000 data points; and wherein the high resolution 3D reconstruction comprises a 3D model of more than 0.5 million data points.
9 . The system of claim 1 , wherein generating the sparse 3D reconstruction comprises performing a data quality check, wherein the data quality check determines an outlier data point having a distance greater than a predefined threshold from a plurality of adjacent data points.
10 . The system of claim 1 , wherein the mobile computing device further comprises a wireless data communication device.
11 . The system of claim 10 , wherein the memory device further comprises instructions that when executed cause the mobile device to execute an operation of transmitting, via a wireless communication device, data comprising one or more of the series of images, the region of interest, the high resolution 3D reconstructions, the measurement, and combinations thereof.
12 . The system of claim 1 , wherein the instructions, when executed, cause the mobile computing device to additionally execute an operation of scanning, via an optical assembly, the surface from a distance of 45 centimeters or less from the surface; and
wherein the series of images are based on visible light.
13 . The system of claim 1 , wherein the elevation of the surface feature is a distance measured relative to a geometric shape defined by the surface surrounding the surface feature.
14 . The system of claim 13 , wherein the geometric shape is one of a line or a plane, the line extending between two points on the surface surrounding the surface feature and the plane being fit to the surface surrounding the surface feature.
15 . The system of claim 13 , wherein the elevation is measured in the z-axis of a three-dimensional coordinate system of which x- and y-axes correspond to a frame of the images.