Template-based reverse engineering of parametric CAD models from point clouds

Even if many Reverse Engineering techniques exist to reconstruct real objects in 3D, very few are able to deal directly and efficiently with the reconstruction of editable CAD models of assemblies of mechanical parts that can be used in the stages of Product Development Processes (PDP). In the absence of suitable segmentation tools, these approaches struggle to identify and reconstruct model the different parts that make up the assembly. The thesis aims to develop a new Reverse Engineering technique for the reconstruction of editable CAD models of mechanical parts’ assemblies. The originality lies in the use of a Simulated Annealing-based fitting technique optimization process that leverages a two-level filtering able to capture and manage the boundaries of the parts’ geometries inside the overall point cloud to allow for interface detection and local fitting of a part template to the point cloud. The proposed method uses various types of data (e.g. clouds of points, CAD models possibly stored in database together with the associated best parameter configurations for the fitting process). The approach is modular and integrates a sensitivity analysis to characterize the impact of the variations of the parameters of a CAD model on the evolution of the deviation between the CAD model itself and the point cloud to be fitted. The evaluation of the proposed approach is performed using both real scanned point clouds and as-scanned virtually generated point clouds which incorporate several artifacts that could appear with a real scanner. Results cover several Industry 4.0 related application scenarios, ranging from the global fitting of a single part to the update of a complete Digital Mock-Up embedding assembly constraints. The proposed approach presents good capacities to help maintaining the coherence between a product/system and its digital twin.