Abstract: A method and apparatus for optically determining the dimension of part surfaces. Particular embodiments describe optical triangulation based coordinate measurement machines capable of accurate measurement of complex surfaces, such as gear teeth and turbine blades. Other embodiments provide highly useful sensors for robot guidance and related purposes. Up to 5 axis sensing capability is provided on surfaces of widely varying form.

Abstract: A method and apparatus for positioning a member in a desired position relative to a surface of an object including providing positioning means for positioning the member, sensing the attitude of the object surface relative to the member or the positioning means using a non-contact sensing means, the attitude being sensed in at least one plane normal to the object surface, and controlling the positioning means using data from the sensing means to position the member at a desired attitude relative to the surface of the object.

Abstract: A computerized system and a method for acquisition, storage, and retrieval of a plurality of image datas corresponding to a plurality of physical inspection areas of a physical surface is disclosed. A graphical interface graphically draws a virtual diagram of the physical surface and a plurality of virtual inspection areas on the virtual diagram. A sensor connected to the interface senses a plurality of image datas of the plurality of physical inspection areas. A display connected to the interface is also provided for selectively displaying the virtual diagram and the image data. An image storage connected to the interface collects the plurality of image datas and names an image file of each image data according to a graphical position of the corresponding virtual inspection area on the virtual diagram.

Abstract: A method for creating a retroreflective image of a surface (or transparent medium) is provided where the retroreflective image is produced by illuminating an area of the surface with light which is reflected therefrom to a retroreflector which returns this light to the surface area. At the surface area, the retroreflected light is then reflected again and imaged to thus form the retroreflected image. In one embodiment, a broad light source is used to image a secondary image of the surface. In another embodiment, the light field produced by the surface is larger than the retroreflective element or group of elements which are then moved. In still another embodiment, a single retroreflective element is used together with a divergent light source.

Abstract: This invention relates to an electro-optical technique which senses form type and other defects on surfaces such as sheet metal or plastic panels. Method and apparatus are disclosed for allowing the inspection of the entire surface of interest from a single point of view while reducing the complexity of defects' optical signatures to simplify their subsequent analysis.

Abstract: A method and apparatus for optically determining the dimension of part surfaces. Particular embodiments describe optical triangulation based coordinate measurement machines capable of accurate measurement of complex surfaces, such as gear teeth and turbine blades. Other embodiments provide highly useful sensors for robot guidance and related purposes. Up to 5 axis sensing capability is provided on surfaces of widely varying form.

Abstract: A method and apparatus for inspecting workpieces for rapid and accurate determination of dimensions and the like. The equipment is electro-optical in nature and there is no contact between the inspecting elements and the workpiece under inspection. An electro-optical sensor is utilized which includes a light source for illuminating at least one edge of a workpiece, a lens for forming an image of the illuminated edge, and an array of photosensitive elements, such a photodiodes, capable of producing an electrical signal in response to light incident thereon. The light, including the edge image, is impinged upon the array and the electrical signals produced correspond to the portion of the edge, its shape, etc. The signals can be rapidly analyzed to provide a determination of a dimension such as length, squareness, curvature, and the like.

Abstract: Method and apparatus for measuring cylinder head combustion chambers and provide inputs to machines which can perform operations to assure that all combustion chambers are at a correct volume.Also disclosed are means for matching volumes of engine assemblies as well as precise machining of gears, turbine blades and other parts.Measurements are ideally made via electro-optical sensors, particularly triangulating types.

Abstract: Methods for improving and calibrating a retroreflection defects determination system are disclosed. The retroreflection system includes a light source which directs light to an area of a surface such that the light is reflected therefrom, a retroreflective member positioned such that the reflected light from the surface area impinges thereon and is thus returned to the surface area and re-reflected therefrom and an imaging device whereby the re-reflected light is imaged as a retroreflection image and scanned for intensity variations. In the identifying method, the retroreflective member of the system has a divergence angle, and the imaging step is repeated after the divergence angle has been appropriately changed. According to the calibrating methods, a first retroreflection image of a system is obtained. Then, one of the test conditions of the system is changed or the test surface is changed. The subsequent retroreflection image is then compared to the first in order to calibrate the system.

Abstract: Methods and apparatus are provided for measuring cylinder head combustion chambers and for providing inputs to machines which can perform operations to assure that all combustion chambers are of a correct volume. Apparatus is provided for matching volumes in gear assemblies as well as for providing precise machining of gears, turbine blades and other parts. Measurements are probably made using electro-optical sensors, particularly of the traingulating type.

Abstract: A method of determining physical characteristics of a surface. Light or other electromagnetic radiation is directed onto a first portion of a surface and the reflected radiation is received such as by a photodiode. The radiation is also directed onto at least two further portions of the surface and located on either side of the proximate to the first portion. The radiation reflected by the further portions is also received. The radiation reflected from the first portion is compared with the radiation reflected from the two further portions. The radiation and comparison steps are repeated and the comparisons are used to determine a physical characteristic of the surface, such as the presence of one or more flaws. In another embodiment, light or other electromagnetic radiation is used to determine object dimension, such as bore dimension.

Abstract: This invention relates to electro-optical sensing of form type and other defects on surfaces such as sheet metal or plastic panels. Method and apparatus are disclosed for detection and quantification of defects such as dents, creases, low spots, flat spots, etc. which are a result of the manufacturing, material handling and assembly process. Surfaces of interest are generally those of automobile body panels, (e.g. hoods, fenders), refrigerator panels, furniture panels, and aircraft panels. Similar applications exist to dies and other formed metallic or plastic parts. Both automatic and human visual methods and apparatus are disclosed. The disclosed invention is also effective on paint defects such as orange peel encountered in automotive and other applications. Assemblies of panels, such as car bodies may also be inspected using the invention, and both fixed and moving (e.g. robotic) sensor versions are disclosed.

Abstract: The invention concerns optical non-destructive test of materials using surface distortions detected by light which is reflected from the surface, retroreflected back to the surface and thence to form an image containing a greatly enhanced view of local deformation. In addition, the method is usable for determining surface characteristics of membranes and the like which can be influenced by sound and other wave energy from tested members and other sources and objects.

Abstract: A method and apparatus for inspecting workpieces for rapid and accurate determination of dimensions and the like. The equipment is electro-optical in nature and there is no contact between the inspecting elements and the workpiece under inspection. An electro-optical sensor is utilized which includes a light source for illuminating at least one edge of a workpiece, a lens for forming an image of the illuminated edge, and an array of photosensitive elements, such as photodiodes, capable of producing an electrical signal in response to light incident thereon. The light, including the edge image, is impinged upon the array and the electrical signals produced correspond to the portion of the edge, its shape, etc. The signals can be rapidly analyzed to provide a determination of a dimension such as length, squareness, curvature, and the like.

Abstract: Disclosed are improvements in the surface inspection method and apparatus invention of our copending application "Panel Surface Flaw Inspection", Ser. No. 579,971, U.S. Pat. No. 4,629,319, which has now come to be described as "DiffractoSight". Particularly disclosed are semi and full automatic techniques for quantifying and locating localized surface distortions. Applications for determination of scratches, paint finish defects and other surface problems are also described.The primary area of application is to cosmetic defects on automobile bodies, appliances, and furniture, and the dies, molds and models and other surfaces used in their manufacture.

Abstract: A method and apparatus for controlling a detector array based optical system using reflected or transmitted light for machine vision is disclosed. The light characteristic such as power (intensity) or distribution of power received by said optical system is detected and an electrical signal indicative of the characteristic is transmitted to a remote control system. The control system then adjusts a light power related variable of the optical system when the received light characteristic signal is deficient. A method and apparatus for linearizing the output of a diode array is also disclosed. An element correction array is set up in a microprocessor and an encoding device providing precise edge movement data is moved past the elements of the diode array so that the data from the encoder and from the diode array can be compared and the difference inputted as offset values for the corresponding positions of the elements in the correction array.

Abstract: A new method and apparatus for fabrication or alignment of fixtures, jigs and structures is disclosed. The invention uses target points on one or more details which are referenced to the overall structure via targets on the details. These targets are monitored by a TV camera unit which is alternatively interfaced to a display for the human operator or a robot to provide position data. The interface may include input from a CAD system which allows display on robot coordinates to be offset by design data of the structure or a part to be located on it. While mainly envisioned for assistance in constructing fixtures for automobile assembly, the disclosed invention is widely useable for all types of construction including aircraft, bridges, boats, buses, houses, buildings and the like. A means for improving resolution of automatically servoed camera based systems is also disclosed.

Abstract: A method and device for sensing the presence and location of an object in a reference plane by directing light along a line prependicular to the plane, defining a ring in that plane encircling said line of light, and sensing, by a change in the condition of the light, the presence of an object on the ring. In a first, non-contacting embodiment, light is directed along a line which is the axis of the ring and directed outwardly and focused at the ring. A circular detector coaxial with the light ring is positioned to sense intrusion onto that ring of an object, and by using a circular diode array detector, one can detect both the presence and location of that object on the ring. According to another contacting embodiment, a disc is placed in the reference plane with the light shining through an opening therein, the disc being movable in any direction in said reference plane. When an object touches the disc at any point and moves it, this changes the location of the aperture through which the light passes.

Abstract: Robotic machines such as coordinate measuring machines, contour projectors and other optical measuring machines are provided wherein a pulsed light is used to "freeze" the dimensional or positional data. The light source of an electro-optical sensor which in motion on the machine during an inspection operation is pulsed responsive to a triggering pulse from an encoder. Where the motion is in more than a single axis, the triggering pulse can be provided from that encoder which experiences the most rapid motion or which is associated with the direction of the greatest dimension change of the part under inspection. Several different forms of position encoding apparatus are also disclosed.

Abstract: Target based machine vision method and apparatus are disclosed, useful for alignment of sensors and other objects affixed to structures, robots and the like.While addressed particularly to alignment of machine vision systems relative to structures, the techniques disclosed are useful with a multitude of different sensors and objects.