Dynamic deformation measurement system in real time and on test benches

Objectives:

The main objective of this project is to investigate advanced systems for real-time analysis and prediction of deformations in collapse and envelope tests of automotive engine air intake tubes, using 3D machine vision techniques.

The aim is to investigate techniques that efficiently and quickly measure the radius of the engine system's rubber tubes in specific areas of the tube, in order to determine their deformation caused by the pressures to which the engine is exposed.

The general objective is associated with the following specific objectives:

- To investigate automatic measurement methods with shorter cycle times, higher frequency of inspections, and high repeatability.

- To determine the exact percentage of diameter reduction under different temperature conditions, always using 3D machine vision techniques, in order to model the deformation and make informed decisions regarding tube designs.

- Investigate geometric analysis algorithms that allow for continuous traceability of diameters using 3D tracking adapted for working with deformable objects.

- Determine in advance phenomena such as collapse, that is, the maximum pressure at which the inner surfaces of the tube come into contact with each other in a radial direction, or the envelope, that is, the available space within the engine, taking into account the relative movements and pressure-induced deformations of the tubes.

- Increase the accuracy of current measurements by 20%, since these are taken with contact and a few seconds after applying pressure, and therefore the process itself often distorts the deformation result.

- Increase the precision of measurements by 35% compared to current measurements, which, being manual, are approximate and directly impact the variability of the measurements. (The person performing the test places the micrometer/caliper in a position approximately equal to that of the previously taken measurement).

- Minimize temperature distortions in the test conditions by eliminating the need to open the chamber and introduce the measuring instruments and the operator's hands, which, being at different temperatures, distort the test conditions.

- Achieve savings for the CIKAUTXO group of approximately €500,000 per year by avoiding redesigns of air intake pipes for the engine system, as this project allows for pre-determining the exact design of the components.