阅读说明：本技术 用于采集物体表面特性的数据和信息的系统和方法 (System and method for collecting data and information of surface properties of an object ) 是由 K·C·刘 G·李 于 2018-10-29 设计创作，主要内容包括：提供一种用于收集物体表面特性的信息和数据的系统,该系统包括投影仪、工作台、第一照相机和第二照相机。投影仪悬挂在工作台的上方,并布置成将光学指示符的随机图案投影到工作台上。光学指示符可以是点、线或其他此类指示符。工作台布置成固定待检查的物体。第一照相机定位在工作台的上方且定位至工作台的一侧,并与工作台成一定角度。第二照相机定位在工作台的上方定位至工作台的相对的一侧,并与工作台成一定角度。第一照相机和第二照相机布置成捕捉投影到物体上的光学指示符的图像。该系统进一步布置成从捕捉的图像中采集信息和数据,并从所采集的信息和数据中确定物体表面特性。(A system for collecting information and data on surface properties of an object is provided that includes a projector, a stage, a first camera, and a second camera. A projector is suspended above the table and is arranged to project a random pattern of optical indicators onto the table. The optical indicator may be a dot, line or other such indicator. The table is arranged to hold an object to be inspected. The first camera is positioned above and to one side of the table and at an angle to the table. The second camera is positioned above the table to an opposite side of the table and at an angle to the table. The first camera and the second camera are arranged to capture images of the optical indicator projected onto the object. The system is further arranged to collect information and data from the captured image and to determine object surface characteristics from the collected information and data.)

1. A system for collecting information and data on a surface property of an object, the system comprising:

a table arranged to support an object;

a projector suspended above the table and arranged to project a pattern of optical indicators towards the table;

a first camera positioned above and to one side of the table and at an angle to the table and arranged to capture an optical indicator projected onto an object; and

a second camera positioned above and to an opposite side of the table and at an angle to the table and arranged to capture an optical indicator projected onto the object;

wherein the system is further arranged to collect information and data from the captured image and to determine the object surface characteristics from the collected information and data.

2. The system of claim 1, wherein the optical indicators are randomly distributed dots.

3. The system of claim 1, wherein the optical indicator is a first series of parallel lines.

4. The system of claim 3, wherein the optical indicator is further a second series of parallel lines perpendicular to the first series of parallel lines.

5. A system for collecting information and data on a surface property of an object, the system comprising:

a table arranged to support an object;

a projector suspended above the table and arranged to project a pattern of optical indicators towards the table in a field of projection;

an optical wedge positioned in the field of projection proximate the projector and arranged to rotate periodically about an axis of the field of projection;

a first camera positioned above and to one side of the table and at an angle to the table and arranged to capture an image of an optical indicator projected onto the object as the optical wedge rotates; and

a second camera positioned above and to an opposite side of the table and at an angle to the table and arranged to capture an image of the optical indicator projected onto the object as the optical wedge rotates;

wherein the system is further arranged to collect information and data from the captured image and to determine the object surface characteristics from the collected information and data.

6. The system of claim 5, wherein the optical indicators are randomly distributed dots.

7. The system of claim 5, wherein the optical indicator is a first series of parallel lines.

8. The system of claim 7, wherein the optical indicator is further a second series of parallel lines perpendicular to the first series of parallel lines.

Technical Field

The present disclosure relates generally to systems and methods for collecting information and data to calculate surface contours, edges, and features of objects. More particularly, the present disclosure relates to systems and methods for projecting optical indicators onto the surface of an object and detecting such optical indicators from two or more viewpoints to calculate surface contours, edges, and features of the object.

Background

In many applications, it is useful to accurately determine the surface characteristics of an object. Such surface characteristics include the contours of the surface, the edges of the surface, and features of the surface (e.g., holes, grooves), among others. With respect to the profile of a surface, the term refers to the shape of the surface, including curves, changes in height, sharp transitions, and the like. For features such as holes and grooves, determining such features includes determining the location of the features on the surface as well as the size of the features. In many commercial activities (e.g., manufacturing various types of components and assemblies, assembling components into systems, inspecting the quality of components and systems, etc.), it is useful, or even crucial, to accurately determine such surface characteristics. Determination of surface properties is also important in industrial research and development, product development and academic research.

In many manufacturing applications, the ability to reproducibly manufacture complex parts is critical to the manufacture and assembly of quality products. When parts have complex surfaces, it is important to ensure that these surfaces are manufactured to specification. For example, when dimensional tolerances are small, even minor deviations from specification can result in mismatched or unsuitable components during assembly of the product. This assurance is typically achieved by post-manufacturing inspection of the components and assemblies. Typically, the surface characteristics of the part are evaluated by visual inspection by a quality control person. This visual inspection may be accomplished by simply visually comparing the surface of the part to the template, or by physically contacting the template to the surface of the part. The quality control personnel can then evaluate how well the surface of the part matches the template and make a determination as to the quality of the part. In another approach, quality control personnel may use measurement equipment to directly measure certain dimensions, features, and contours to assess the quality of a part.

It will be appreciated that typical visual and manual inspection techniques employed by quality control personnel can be time consuming and lead to inconsistent results. There is a need for improvements in the art to provide systems and methods for collecting information and data to accurately and precisely calculate surface contours, edges, and features of objects.

Disclosure of Invention

In one embodiment, a system for collecting information and data on a surface characteristic of an object comprises: a projector, a surface (e.g., a table) supporting an object under examination, a first camera, and a second camera. A projector is suspended above the table and arranged to project a pattern of random optical indicators onto the table. The optical indicator may be a dot, a line, a combination of both, or any such indicator. The first camera is positioned above and to one side of the table and at an angle to the table. The second camera is positioned above and on an opposite side of the table and at an angle to the table. The first camera and the second camera are arranged to capture images of the optical indicator projected onto the object. The system is further arranged to collect information and data from the captured image and to determine object surface characteristics from the collected information and data.

In another embodiment, a system for collecting information and data on a surface characteristic of an object comprises: a projector, an optical wedge, a surface (e.g., a stage) supporting an object under inspection, a first camera, and a second camera. A projector is suspended above the table and arranged to project a pattern of random optical indicators onto the table. Within the field of projection, an optical wedge is positioned near the projector. The wedge is arranged to refract the pattern projected from the projector and is further arranged to rotate periodically about the axis of the field of projection. The first camera is positioned above and to one side of the table and at an angle to the table. The second camera is positioned above and on an opposite side of the table and at an angle to the table. The first camera and the second camera are arranged to capture images of the optical indicator projected onto the object as the optical wedge is rotated. The system is further arranged to collect information and data from the captured image and to determine object surface characteristics from the collected information and data.

Drawings

In the accompanying drawings, structures of exemplary embodiments of the disclosed systems, methods and apparatus are shown which are described in connection with the detailed description provided below. Identical elements are denoted by the same or similar reference numerals, where appropriate. Elements shown as a single component may be substituted for multiple components. Elements shown as multiple components may be replaced by a single component. The drawings may not be to scale. The scale of certain elements may be exaggerated for illustrative purposes.

Fig. 1 schematically illustrates a perspective view of an exemplary system for acquiring information and data of a surface characteristic of an object using a generally circular optical indicator.

Fig. 2 schematically shows a top view of the system of fig. 1.

FIG. 3 schematically illustrates a perspective view of another exemplary system for acquiring information and data of a surface characteristic of an object using substantially parallel linear optical indicators.

Fig. 4 schematically illustrates a perspective view of yet another example system for acquiring information and data of a surface characteristic of an object using a first set of substantially parallel linear optical indicators and a second set of substantially parallel linear optical indicators substantially perpendicular to the first set of linear optical indicators.

FIG. 5 schematically illustrates an optical wedge positioned near a projector for use with the system disclosed herein.

Fig. 6 schematically shows a perspective view of another exemplary system for acquiring information and data on properties of a surface of an object, in particular for determining the depth of a hole in the surface of the object.

Fig. 7 schematically illustrates a front view of a camera for use with the system disclosed herein.

Detailed Description

The apparatus, systems, arrangements and methods disclosed herein are described in detail by way of example and with reference to the accompanying drawings. It is to be understood that the disclosed and described examples, arrangements, configurations, components, elements, instruments, methods, materials, etc., are capable of modifications and may be desirable for particular applications. In this disclosure, any identification of particular techniques, arrangements, methods, etc., is related to or is merely a general description of such techniques, arrangements, methods, etc., presented. The identification of specific details or examples is not intended, and should not be construed, as mandatory or limiting unless explicitly specified otherwise. Selected examples of instruments, arrangements and methods for accurately acquiring information and data of surface properties of an object will be disclosed and described in detail below with reference to fig. 1-7.

Fig. 1 schematically illustrates a perspective view of a system 10 for acquiring information and data on surface properties of an object 20. The system 10 includes a surface (e.g., table 30) for supporting an object, a projector 40, a first camera 50, and a second camera 60. The projector 40 is positioned directly above the table 30 and projects a series of randomly positioned optical indicators (e.g., generally circular dots 70) that are displayed on the table 30. It will be appreciated that when the object 20 is placed on the table 30, a plurality of points 70 will be projected onto and displayed on the object 20. The field of projection 80 of the projector 40 is wide enough to project the spot 70 on all areas of the table 30. In the system 10 shown in FIG. 1, a central axis (not shown) through the field of projection 80 is perpendicular to the table 30. It will be appreciated that in such an arrangement, the optical indicator (e.g. point 70) is projected onto the table 30 without any substantial distortion due to the projection angle. It will be further appreciated that if the central axis of the projection field is at an angle to the table, the point projected onto the table will undergo some deformation (i.e. assume an elliptical or other rectangular shape). However, it will be understood that such angles and variations may be considered in any of the algorithms and methods described herein. In the present disclosure, the optical indicators are shown in a certain arrangement and spacing; it will be understood, however, that such illustrations are presented in a non-limiting manner to facilitate an understanding of the systems and methods. Alternative arrangements and spacing of the projected optical indicators are also contemplated herein and are part of the present disclosure.

As shown in fig. 1, the surface of the object 20 has a contour, and for demonstration purposes, the object 20 includes a number of features, including a pair of holes 90, 100 and a slot 110. The first camera 50 is positioned above the table 30 and to one side of the table 30, and the second camera 60 is positioned above the table 30 and to the opposite side of the table 30. The first camera 50 and the second camera 60 are angled downward toward the table 30 such that the field of view 120 of the first camera 50 captures the entire table 30 and the field of view 130 of the second camera 60 also captures the entire table 30.

When projecting the random series of dots 70 onto the object 20, the first camera 50 may be arranged to capture a first image of the object 20 from a first viewpoint and the second camera 60 may be arranged to capture a second image of the object 20 from a second viewpoint. Fig. 2 is a schematic view of system 10 from directly above system 10. As shown, the first camera 50, the second camera 60, and the projector 40 are aligned collinearly along a line 140. Also, as shown in fig. 1, the first camera 50 and the second camera 60 may be positioned at the same upward distance as the table 30 and laterally spaced from the table 30, and oriented at the same (but opposite) angle to the table 30. Thus, it will be understood that the first viewpoint of the first camera 50 is directly opposite the second viewpoint of the second camera 60. Although the system 10 shown in fig. 1 depicts the first camera 50, the second camera 60, and the projector 40 as being collinear, and the first camera 50 and the second camera 60 being positioned at the same upward distance as the table 30 and laterally spaced from the table 30 (i.e., at the same but opposite angle), other arrangements of components are contemplated. The first camera 50 and the second camera 60 may be positioned at different distances from the table 30 and at different angles with respect to the table 30. However, in each arrangement, the projector 40 projects the optical indicator onto the object 20 and a pair of cameras captures images of the optical indicator from two different perspectives.

Once the first camera 50 captures a first image and the second camera 60 captures a second image, the two images may be analyzed to determine surface characteristics of the object 20. Analyzing the first and second images is performed using algorithms and other methods nested in software code and running on a server, computer, or other computing device. The process of analyzing the first and second images begins by identifying a single point in the first and second images. The random pattern of dots 70 helps to identify each individual dot 70. A pattern having a plurality of points may be recognized in the first image and the same pattern may be recognized in the second image. Thus, corresponding points of the recognized patterns in the first and second images may be paired and considered to be the same point. Each point projected onto the object can be identified in the first and second images by the process of identifying a number of patterns in the first and second images. Once each point is identified in the first and second images, the two images of the point may be compared to help determine the surface characteristics of the object.

Although the method of determining surface characteristics described herein relies primarily on the projection of random optical indicators onto the object to be inspected, such a method may use additional data and information. For example, due to the arrangement of the system 10, a number of "known" factors may be used with the data and information acquired from the first and second images to determine the surface characteristics of the object. For example, the location of the projector 40 is known, the characteristics of the proxel 70 are known, and the locations of the first camera 50 and the second camera 60 are known. That is, the size of the projected dots from the projector 40 (and thus the size of the projected dots at each incremental distance from the projector) is known, the distance from the projector 40 to the stage 30 is known, the distance and angle of the first camera 50 relative to the stage 30 is known, and the distance and angle of the second camera 60 relative to the stage 30 is known.

By combining the list of known factors with the shape and position of each point appearing on the first and second images, the object surface characteristics can be determined. In one example, if the first and second images capture only a portion of a point, the point may be determined to span an edge of an object of the object 20 or an edge of a feature of the object 20 (e.g., an edge of a hole or a slot). In another example, if the point captured by the first and second images is non-circular, i.e., elliptical or other rectangular, it may be determined that the point is projected onto the surface of the object at an angle relative to the surface of the table. By considering the projected size of the dots, the distance of the projector to the table, and the distance and angle of the first and second cameras 50, 60, the profile of the object surface at the point projection can be determined. It will be appreciated that evaluating a large number of points, in particular a large number of adjacent points, may be used to determine the contour of the surface, the edges of the object and the features of the surface.

In one embodiment, the projector is arranged to project approximately 40,000 points onto the work area of the table. In this embodiment, the stage is approximately 450 mm X450 mm. In another embodiment, the projector may project a plurality of high intensity spots randomly or systematically spread over a plurality of spots. Such high intensity points may be easily identified in the captured image and may be used to direct multiple points on the images captured by the first and second cameras. In another embodiment, the projector is located between about 0.4 meters and about 0.5 meters from the stage. At such distances, the diameter of the projected spot is about 300 microns.

In another embodiment, the projector may be fixed at the end of the robot arm and may be moved relative to the object while projecting the point onto the object. Such an arrangement may increase the surface area of the object under inspection and may collect information and data on the sides of the object as well as on the top of the object. Such an arrangement may further be used to fix multiple images of any surface of an object, and thus, information and data on that surface may be increased, so that the accuracy of determining the size and contour of the object may be further improved. Other known factors that may be incorporated into the analysis, as described herein, are the position and angle of the projector on the robotic arm, and how the position and angle change as the robotic arm moves to change the projection of the optical indicator on the object. In another embodiment, the projector may first project a template of the contour of the object to be analyzed. The object may be placed on the template to ensure that it is placed on the table in an optimal manner during the acquisition of information and data.

Fig. 3 schematically illustrates a perspective view of another system 200 for acquiring information and data on surface characteristics of the object 20. The system 200 of fig. 3 is similar to the system 10 of fig. 1 and 2; however, the optical indicator is a series of parallel lines 210. The table 30, projector 40, first camera 50, and second camera 60 are positioned as shown in the system 10 of fig. 1 and 2, respectively, and as previously described herein. The object 220 of fig. 3 comprises three apertures 230, 240, 250. The first image captured by the first camera 50 and the second image captured by the second camera 60 may be used to determine the location and size of the holes 230, 240, 250 in the object 220. The interruptions in the parallel lines 210 may indicate the edges of the holes. In one embodiment, the line 210 may be projected multiple times at different locations on the table 30, and the first camera 50 and the second camera 60 may capture images at each different location. All captured images may be considered collectively to determine the location and size of the apertures 230, 240, 250.

Fig. 4 schematically illustrates a perspective view of another system 260 for acquiring information and data on surface characteristics of the object 20. The system 260 of FIG. 3 is similar to the system 200 of FIG. 3; however, the optical indicator is two series of parallel lines 270, where the first series of parallel lines is perpendicular to the second series of parallel lines. The table 30, projector 40, first camera 50, and second camera 60 are each positioned as shown in the system 200 of fig. 3.

FIG. 5 shows another embodiment in which a rotating wedge optic 300 is positioned between projector 40 and an object (not shown, but similar to the object shown in FIGS. 1-4). Such an arrangement facilitates determining object surface characteristics by capturing multiple successive images of the object. In such an arrangement, projector 40 projects an optical indicator (e.g., a series of dots) through wedge optic 300, which refracts the series of dots before projecting them onto the object. As the wedge rotates about axis 310, a series of points move position on the object and provide additional information as the points fall in different ways on various contours, features, and edges of the surface of the object. The optical wedge 300 may be rotated and indexed by a motor and belt assembly (not shown). That is, wedge 300 may be rotated multiple times, each time by a particular angular increment. With each rotation, the first camera and the second camera capture images of a point on the object. With known angular increments, this information can be combined with information and data collected from multiple captured images and other known factors to accurately and precisely determine object surface characteristics.

In one embodiment, wedge 300 is rotated in increments of approximately 2 degrees. Wedge optic 300 may rotate for about 100 milliseconds and the first camera and second camera capture images for each rotation in about one second. In such an arrangement, typically five sets of captured images are sufficient to accurately and precisely determine the object surface characteristics. Thus, the process of determining the surface characteristics is efficient.

Fig. 6 schematically shows a perspective view of another system 400 for acquiring information and data of surface properties of an object 410, and in particular the position and size of a hole 420 including the depth of the hole 420. The system 400 includes a table 30, a projector 40, a first camera 50, and a second camera 60. In this embodiment, the points are projected at a slight angle relative to the stage 30. As shown, the result is a series of points 430 projected onto the wall of the bore 420. If the hole is formed through the entire thickness of the object, or if the hole is countersunk (i.e., the hole is not formed through the entire thickness of the object), the point 430 may also be projected through the hole or on the bottom of the hole. The second camera 60 may capture a point 430 projected on the wall of the hole 420 or the bottom of the countersink. The characteristics (including depth) of the hole 420 may be determined based on the captured images and known factors of the position and angle of the projector 40.

Fig. 7 schematically shows an embodiment of a camera 500. The camera 500 includes an aperture 510 surrounded by a series of light sources 520. The light source 520 may enhance the quality and detail of the images captured by the camera 500. In one embodiment, the light source is a Light Emitting Diode (LED).

The foregoing description of the examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limited to the forms described. Many modifications are possible in light of the above teaching. Some of which have been discussed and others will be understood by those skilled in the art. The examples were chosen and described in order to best explain the principles of various examples as suitable for the particular use contemplated. Of course, the scope is not limited to the examples described herein, but may be used by one of ordinary skill in the art in any number of applications and equivalent devices.