The value of multi-camera DIC technology is ultimately demonstrated through practical application cases. After years of technological development and market promotion, multi-camera DIC has been widely adopted in various industries, accumulating a wealth of successful case studies. This article will provide a detailed introduction to typical application scenarios and implementation effects of multi-camera DIC technology in different industries.
Aerospace
Case 1: Static Test of a Large Passenger Aircraft
During the full-aircraft static test prior to airworthiness certification, a multi-camera DIC system was used to measure deformation across the entire aircraft. The test subject was the entire fuselage, and the measurement area covered more than 200 square meters.
Project challenges :
- The measurement area is extremely large, and traditional methods cannot achieve full-field measurement.
- Deformation data needs to be acquired synchronously under multiple loading conditions.
- The on-site environment is complex, and temperature and vibration conditions are difficult to control.
Solution :
A measurement array of 48 high-resolution industrial cameras was deployed, employing a layered measurement strategy. Wide-angle cameras were responsible for overall deformation monitoring, while local high-resolution cameras focused on key connection points and areas of concentrated strain.
Implementation results :
The full-field three-dimensional displacement and strain distribution data of the fuselage under different load conditions were successfully obtained, and three strain concentration areas that were not predicted in the design stage were discovered, providing key basis for structural optimization design.
Case Study 2: Monitoring the Deployment Process of Satellite Solar Panels
The high-speed dynamic measurement of the solar array deployment process of a certain communication satellite places extremely high demands on the temporal and spatial resolution of the measurement system.
Project challenges :
- The unfolding process lasts only about 10 seconds, requiring the capture of millisecond-level details.
- The solar array is a large, flexible structure with complex deformation characteristics.
- Conducted in a vacuum simulation environment, where contact sensors cannot be used.
Solution :
A circular array of 16 high-speed cameras was used, with a maximum acquisition speed of 10,000 frames per second. Through precise timing control and multi-camera data fusion, the three-dimensional motion trajectory of the entire solar array deployment process was obtained.
Implementation results :
The motion coordination of each hinge mechanism during the deployment process was fully recorded, and a small rebound phenomenon was discovered at the end of the deployment, providing experimental basis for the design improvement of the solar panel locking mechanism.
auto industry
Case Study 3: Vehicle Body Deformation Analysis in a Collision Test
Automotive crash safety testing is a key application area for multi-camera DIC technology. One vehicle manufacturer has adopted a multi-camera DIC system to replace traditional contact sensors for crash test measurements.
Project challenges :
- The collision process is extremely brief (tens of milliseconds), requiring extremely high acquisition speeds.
- The deformation is enormous, and the speckle pattern needs to adapt to the large deformation without falling off.
- Post-collision processing space is limited, and the equipment must withstand the impact of the collision.
Solution :
Twelve high-speed cameras are deployed, employing a special hard speckle diaphragm and shock-resistant mounting scheme. The system trigger delay is controlled to within 1 microsecond, ensuring strict synchronization of all cameras.
Implementation results :
Complete deformation field data of the vehicle body throughout the entire collision process was obtained, including key indicators such as B-pillar acceleration, passenger compartment intrusion, and A-pillar rotation angle. Comparison with traditional sensor data showed a measurement error of less than 3%.
Case Study 4: Battery Pack Structure Testing for New Energy Vehicles
As a core component of new energy vehicles, the structural safety of the power battery pack is of paramount importance. A battery manufacturer uses a multi-camera DIC system to conduct mechanical reliability testing of the battery pack.
Project challenges :
- The battery pack surface is made of metal and has a strong reflective surface.
- It is necessary to measure the response of the internal module under external loads.
- The testing cycle is long, requiring the equipment to operate stably for an extended period.
Solution :
A low-reflection speckle process and polarized light source solution were custom-developed to address the characteristics of metal surfaces. The system adopts an industrial-grade design and can operate continuously for more than 72 hours.
Implementation results :
The full-field deformation of the battery pack under test conditions such as compression, extrusion, and vibration was successfully measured, and the deformation coordination problem between the shell and the internal modules was identified, providing strong support for product structure optimization.
civil Engineering
Case 5: Load Test of Ultra-Large Span Bridges
A cross-sea bridge with a main span exceeding 1,500 meters used a multi-camera DIC system for static and dynamic load tests during its final acceptance.
Project challenges :
- The measurement span is extremely large, and the coverage area of a single measurement is unprecedented.
- The site is located at sea, where ambient light and weather conditions vary drastically.
- The bridge was maintained and open to traffic during the testing period, but the testing window was limited.
Solution :
A large-scale measurement array composed of multiple industrial cameras was used to achieve synchronous control of multiple measurement areas. A dedicated anti-interference algorithm was developed to cope with complex lighting conditions on the sea surface.
Implementation results :
For the first time, simultaneous full-field deformation measurement of a long-span bridge was achieved, obtaining the three-dimensional deformation surface of the main girder under various load levels. The measurement accuracy is better than 0.5 mm, meeting the design verification requirements.
Biomechanics
Case Study 6: Analysis of Human Joint Movement
In the fields of sports medicine and rehabilitation engineering, multi-camera DIC technology is used to accurately measure the movement and deformation of human joints.
Project challenges :
Human tissues are soft tissues with complex deformation patterns.
- Skin spots are difficult to keep stable for a long time.
- Measurements need to be performed under conditions close to physiological environments.
Solution :
A motion capture system consisting of eight industrial cameras was used to perform measurements by drawing specialized speckle patterns on the skin surface. A skin marker tracking algorithm was developed to achieve indirect measurement of deep tissue deformation.
Implementation results :
The full-field strain distribution of the knee joint during daily activities such as walking and running was successfully obtained, providing quantitative evidence for the study of sports injury mechanisms and the formulation of rehabilitation programs.
As the above examples demonstrate, multi-camera DIC technology has extremely wide applications, covering almost all industrial and scientific research scenarios requiring full-field deformation measurement. Whether your measurement object is a massive aircraft fuselage, a spherical surface, a large-scale structure, or soft biological tissue, multi-camera DIC technology can provide a reliable solution.
With years of experience implementing DIC projects across various industries, we can tailor measurement solutions to your specific needs. Feel free to contact our technical team to learn more about the specific applications of multi-camera DIC technology in your industry.
