Nguyen
Nguyen
Automation in Construction
journal homepage: [Link]/locate/autcon
Comparison of point cloud data and 3D CAD data for on-site dimensional T
inspection of industrial plant piping systems
⁎
Cong Hong Phong Nguyena, Young Choib,
a
Department of Mechanical Engineering, Graduate School, Chung-Ang University, Seoul, Republic of Korea
b
School of Mechanical Engineering, College of Engineering, Chung-Ang University, Seoul, Republic of Korea
A R T I C L E I N F O A B S T R A C T
Keywords: Inspection is vital in industrial plant construction and management. However, traditional inspection methods
Point cloud that rely on human involvement and paper documentation are becoming untenable as modern industrial plants
As-built inspection are becoming larger and more complex than legacy facilities. Hence, an efficient and robust method is required
CAD-vs-scan to support the inspection of modern industrial plants. In this paper, an improved technique relying on terrestrial
Distance-based deviation analysis
laser scanning (TLS) for data acquisition and normal-based region growing and efficient random sample con-
Geometric parameter comparison
sensus (RANSAC) for point cloud data processing is proposed for the on-site dimensional inspection of the piping
systems of an industrial plant. Consequently, the as-built condition of the plant is assessed via a distance-based
deviation analysis and a comparison of geometric parameters between the as-designed and as-built models. The
method is validated using a dataset acquired from a compartment of a ship has verified the robustness and
reliability of the proposed approach.
1. Introduction from the compartment of a ship, which is a type of industrial plant, was
used to validate the efficiency and robustness of the proposed method.
Piping systems play an important role in the operation of industrial
plants as they appear widely in heating, ventilation, and air con- 2. Literature review
ditioning (HVAC) systems in terrestrial industrial factories and used for
supporting marine facilities. The inspection of piping systems in such Since the proposed approach is a combination of existing and effi-
plants is usually performed during the following three stages in the life cient methods, a literature review is required. Two following sections
cycle of a facility: production, post-production, and on-site inspection include a review of the existing literature on the laser scan data pro-
during construction [1]. Among these, on-site inspection poses the most cessing for the as-built modeling of mechanical, electrical, and
significant challenge in achieving operational efficiency and robust plumbing (MEP) constructions and utilization of the laser scan data for
results due to the large scale of the facilities. As mentioned in [2], it is the inspection of large-scale objects.
difficult to monitor and record the inspection results as doing so re-
quires significant manual operation, and therefore, needs tremendous 2.1. Point cloud processing for the as-built modeling of MEP constructions
human resources. Hence, a new method is needed to improve the au-
tomated monitoring and quality assurance of industrial plants. Various studies have been conducted on the data processing of point
As any dimensional deviation in the construction of the piping clouds obtained from cylindrical objects. Chaperon et al. [3] proposed a
system could lead to a serious problem in the operation of the entire method based on a Gaussian image and random sampling to detect and
plant, a robust and efficient method for on-site dimensional inspection extract the data points of cylindrical objects. The result was reliable and
is required. In this paper, a method to support the decision-making for robust, but the computational efficiency when applying the method to
the inspection of industrial piping systems is proposed. The proposed large data sets was not validated. Son et al. developed two related
method involves point cloud data processing for object segmentation techniques, relying on the curvature computation [4] and prior
and extraction to aid a comparative assessment via a distance-based knowledge, using a three-dimensional (3D) CAD database [5], whereas
deviation analysis of the geometric parameters of the as-built piping Lee et al. [6] used a skeleton method to reconstruct an as-built model of
components required for the inspection. A sample dataset acquired a piping system from the point cloud data. Kawashima et al. [7,8]
⁎
Corresponding author at: School of Mechanical Engineering, College of Engineering, Chung-Ang University, 84 Heukseok-ro, Dongjak-gu, Seoul 06974, Republic of Korea.
E-mail address: yychoi@[Link] (Y. Choi).
[Link]
Received 12 September 2017; Received in revised form 13 February 2018; Accepted 2 March 2018
0926-5805/ © 2018 Elsevier B.V. All rights reserved.
C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
suggested a method using normal-based region growing for the seg- proposed. The proposed method utilizes the advantages of as-built
mentation and cylinder fitting for the segmentation and recognition of modeling in providing the geometric parameters, as well as corre-
piping components. The recognition rate in the above studies was high, sponding data points of the piping components to support inspections.
at > 80%. Other notable studies are those performed by Patil et al. [9], Although only a simple comparison was performed between as-built
Liu et al. [10], Czerniawski et al. [11], Bosche et al. [12], and Dimitrov and as-designed models, its role in the on-site inconsistency inspection
et al. [13]. Although various effective methods for point cloud data is highly important because of its ability to balance the quality and cost
processing exist, the complexity of the industrial plants renders that the of the inspection.
use of a single-algorithm method that works perfectly in every case is
infeasible. Also, the use of a multi-step method may increase the effi-
ciency and reduce any of the disadvantages associated with each al- 3. Methodology
gorithm.
The proposed method is divided into two main stages: point cloud
data processing and as-built condition assessment based on the point
2.2. Utilization of laser scan data for the inspection of large-scale of objects cloud processing result (Fig. 1). As the scan data obtained from an as-
built industrial plant are expected to be highly complex, including the
Terrestrial laser scanning (TLS) has been employed as an optimal noise and data points corresponding to the non-piping components, a
and available method to capture the geometric data of the as-built in- combined method is developed for a more robust and efficient pro-
dustrial plants as it can rapidly capture the current configuration and cessing. Details of the method are described in Section 3.1. To assess the
layout of the plants with a high accuracy [12]. The idea of utilizing TLS dimensional quality of the as-built plant, the geometric parameters of
as a tool for supporting construction inspection is not new. In fact, it has the recognized components are extracted and compared against their
been applied for the inspection of other types of large-scale construc- as-designed specifications as derived from the CAD data in stereo-
tions such as tunnels and structural constructions [14–18]. The ad- lithography (STL) format. The derived quality metrics include the mean
vantage of the TLS technology has been demonstrated in the application distance error (MDE), point distance error (PDE), and other geometric
of progress monitoring [2,19–22]. However, the extant research on parameter deviations between the as-designed CAD and as-built scan
using TLS for the dimensional inspection of MEP constructions is lim- data. These metrics provide useful information for aiding decision-
ited [1,23,24]. Safa et al. in [1] proposed an automated workflow for making during the inspection of a plant. This process is described in
the dimensional quality control of manufactured pipe spools. In [1], the Section 3.2.
authors highlighted that the three important stages in the construction
of piping systems in which the quality must be controlled are: pro-
duction, post-production of the piping spools, and on-site construction. 3.1. Point cloud data processing
However, it is noted that little attention is paid to the on-site dimen-
sional inspection of MEP constructions, which plays a crucial role in 3.1.1. Related works
plant construction and management. Both Nahangi et al. in [23] and As mentioned above, the proposed approach is based on the com-
Anil et al. in [25] concluded deviation analysis as the most effective bination of existing robust and efficient methods. In this study, the two
dimensional inspection method. However, in large-scale constructions, most efficient algorithms in point cloud data processing for as-built
such as an industrial plant, performing only a deviation analysis is not modeling, namely, normal-based region growing [26] for point cloud
typically effective. This is possibly due to the complexity and size of the segmentation and an efficient random sample consensus (RANSAC)
corresponding object. Also, when the scale of the system is very large, [27] for feature recognition and parameter extraction were combined to
including a vast number of components, performing a direct deviation enhance the efficiency and productivity. Also, common preprocessing
analysis is not suitable. Therefore, it is not sufficient for checking the algorithms including octree-based downsampling and point-to-mesh
consistency of an as-built construction. iterative closest points (ICP) for registration were used. A comprehen-
In this paper, a combined method based on a comparison of the sive description of the point cloud processing method is discussed in the
geometric parameters and distance-based deviation analysis is following three sections.
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
Fig. 2. Point cloud registration. (a). Point cloud data and CAD data. (b). Point cloud data registration. (c). Distance analysis for validation.
3.1.2. Preprocessing to the octree cell are replaced by the center of the cell; i.e., the above
[Link]. Point cloud alignment and downsampling. A key initial step in points are compressed into an octree cell. Fig. 3 depicts the utilization
point cloud processing is the alignment of the as-built point cloud of an octree for downsampling.
obtained from a terrestrial laser scanner, to the corresponding as-
designed CAD data in an STL-formatted mesh representation. The
registration process consists of two steps. First, a rough alignment is [Link]. Planar object removal. As mention in [28], planar objects such
performed manually, and then a point-to-mesh ICP algorithm is utilized as floors, walls, and ribs may contain numerous data points, making the
for a fine registration of both the models. Fig. 2 depicts an example of model complex. As a result, the computation time increased and the
the alignment procedure. processing result becomes unstable. Therefore, a removal process
Here, a downsampling is necessary to reduce the size of the data and reduces the size and complexity of the input data to enable further
computational cost because the size of the original scan data is massive. processing. In the proposed approach, the efficient RANSAC described
In this work, octree-based downsampling is performed. First, the input in [27] was used to detect and remove the planar objects. The
point cloud is spatially portioned, and a sufficient octree is computed. convergence error value should be chosen as larger than the tolerance
Based on the choice of the depth level, all the data points corresponding of the laser scanner. In this case, based on the experiments, the
convergence error was set as 0.035 m because the scanner had a
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
Fig. 4. Planar object removal process. (a). Input point cloud. (b). Planar object detection. (c). Planar object removal.
tolerance of 0.006 m at 100 m. Also, to avoid over-removal, a constraint depends on the estimation of the normal of the points. Typically, two
ensuring that a single planar object is removed only if the point cloud methods are employed, k-nearest neighbors (KNN) or fixed distance
size is larger than a pre-defined threshold is added. The magnitude of neighbors (FDN). The input values of both the KNN and FDN methods
the threshold can be defined based on experiments. Fig. 4 illustrates the are chosen based on the density of the point cloud. In this case, the KNN
planar object removal process. method was applied. Because the data points after downsampling by
the octree compression are organized, it is suitable to select the number
of KNN based on the structure of the square block, as illustrated in
3.1.3. Normal-based region growing segmentation
Fig. 5(b). In this work, the KNN number is set as 24 (a 5 × 5 block), a
After the preprocessing, the input point cloud was segmented using
value obtained from the experiments.
the normal-based region growing algorithm. In this work, this process
The region growing algorithm requires two types of constraints of
was executed following the work described in detail in [26], being re-
local connectivity and smoothness. In this case, a k-dimensional (k-D)
implemented and provided in [29]. In brief, the process is as described
tree was constructed to connect the points, and angle threshold θth,
below:
which stands for the smoothness constraint, was set as 30° to avoid
over-segmentation.
• Step 1: From input point cloud {P}, the point with the lowest cur-
vature is picked, removed from {P},and add to seed point set {S}
• Step 2: For each point in {S}, 3.1.4. Cylinder feature recognition and parameter extraction
○ The k nearest neighbors available in {P} are examined
To detect and extract the parameters of cylindrical objects, the ef-
○ If the angle difference between the neighbor and pi, θ, is smaller
ficient RANSAC method proposed by Schnabel et al. [27] was used due
than θth, this neighbor is removed from {P} and added to region
to its efficient shape detection. Since most piping components, in-
{Ri}
cluding pipelines and joints, are cylindrical, the above algorithm is
○ If the curvature is smaller than cth, is added it to seed point set
applied to obtain only the cylindrical components. To define a cylinder
{S}, and step 2 is repeated
in the Cartesian space, the following seven geometry parameters are
○ If no new point exists that could be selected in {S}, then {Ri} is
used: center axis vector components (dx, dy, dz), coordinate of a single
saved to result segment set {R}.
point on the center axis (p1, p2, p3), and radius of the cylinder (rc).
• Step 3: If all the points in {P} have been tested, result segment set
Applying the efficient RANSAC algorithm proposed in [27], a best-fit
{R} is returned.
cylinder model is obtained, and its parameters are extracted. Distance
(τth) and angle (θth) thresholds are required for the algorithm. Because
Fig. 5(a) displays an illustration of the region growing segmentation
there is no common rule for setting these thresholds, their optimal
method.
values are found from the experiments using the input data.
The robustness of the normal-based region growing algorithm
Fig. 5. Normal-based region growing. (a). Region growing. (b). k-Nearest neighbor selection based on a square block.
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
Fig. 7. Experimental data. (a). CAD data in STL format. (b). Point cloud data.
Fig. 8. Point cloud data processing result. (a). Input point cloud. (b). Planar object removal. (c) Normal-based region growing. (d). RANSAC cylinder detection.
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
Fig. 9. Two reasons causing components to not be recognized. (a). Occlusion due to the line of sight. (b). Diffusion of laser light.
Fig. 10. Combined method in the case of missing data. (a). Input point cloud. (b). Normal-based region growing. (d). RANSAC cylinder detection.
Fig. 11. Experimental region. (a) Point cloud scan data. (b) CAD data in STL format.
analysis of the accuracy of the point cloud registration process could depicts an example of the PDE computation for a piping component
also help achieve a more robust result. chosen from the sample list. The chosen pipes are marked by rectan-
In general, except in certain unrecognized cases, the point cloud gular boxes and numbered from 1 to 6. Both Table 4 and Fig. 12 present
processing technique described here is sufficiently robust and reliable the error of the as-built model when it is correctly constructed; clearly,
for use in a facility inspection. the errors are small and acceptable. The PDE analysis, as shown in
Fig. 12, also indicates the occlusion regions, providing useful in-
4.2.2. As-built condition assessment formation to inspectors about the status and quality of the input data. If
Figs. 11 and 12 and Table 4 present an example of the as-built di- there are missing data in the regions of interest for the inspection, the
mensional assessment process. Fig. 11 displays the sample region that is inspectors would be advised to adjust the scanner position to obtain the
assessed in the experiment and reported in Table 4, whereas Fig. 12 required data.
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C.H.P. Nguyen, Y. Choi Automation in Construction 91 (2018) 44–52
Fig. 12. Point distance error analysis. (a) Point cloud data and CAD data. (b) PDE analysis result.
5. Conclusion
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