Abstract: An inspection station for manufactured components includes a framework and a plurality of cameras. The framework has of a plurality of vertically stacked and spaced apart plates. Each plate defines a central orifice. The central orifices of each plate are aligned along an axis. The manufactured components are configured to freefall through the central orifices defined by the plates. The plurality of cameras is secured to the framework. Each camera is focused toward a region within the framework to capture images of the manufactured components. The plurality of cameras is arranged in an array that extends radially about the axis. At least one of the cameras is positioned at an angle above a horizontal plane that is perpendicular to the axis and intersects the region within the framework. At least one of the cameras is positioned at an angle below the horizontal plane.

Abstract: A sorting system for inspected parts includes a storage assembly, a conveyance system, and a controller. The storage assembly has a plurality of bins configured to receive and store the inspected parts. The conveyance system is configured to deliver the inspected parts to the storage assembly. The controller programmed to, assign part types to each of the plurality of bins. The controller is further programmed to operate the conveyance system to deliver each of the inspected parts to one of the plurality of bins having a matching part type. The controller is further programmed to, in response to a full condition of the storage assembly, empty the inspected parts from a first the plurality of bins.

Abstract: An inspection system includes a base, an array of fixtures, and a plurality of sensors or light sources. Each fixture has a first portion rotatably secured to the base and configured to rotate about a yaw axis and a second portion rotatably secured to the first portion and configured to rotate about a pitch axis. Each sensor or light source is secured to one of the fixtures and is configured to direct light at yaw and pitch angles relative to the base.

Abstract: A computer-implemented method of automatically generating inspection templates of a plurality of known good fasteners to identify fasteners at an inspection station is provided. The method includes providing a data entry mechanism to provide content needed to identify a plurality of unidentified mixed fasteners. The method also includes storing the content in a database, extracting the content from the database and creating the inspection templates from the extracted content. Each of the templates including a fastener profile and a set of features. Each of the features includes a range of acceptable values. Each of the templates has a fastener identification code associated therewith.

Abstract: An inspection station for manufactured components includes a framework and a plurality of cameras. The framework has of a plurality of vertically stacked and spaced apart plates. Each plate defines a central orifice. The central orifices of each plate are aligned along an axis. The manufactured components are configured to freefall through the central orifices defined by the plates. The plurality of cameras is secured to the framework. Each camera is focused toward a region within the framework to capture images of the manufactured components. The plurality of cameras is arranged in an array that extends radially about the axis. At least one of the cameras is positioned at an angle above a horizontal plane that is perpendicular to the axis and intersects the region within the framework. At least one of the cameras is positioned at an angle below the horizontal plane.

Abstract: An inspection system includes a base, an array of fixtures, and a plurality of sensors or light sources. Each fixture has a first portion rotatably secured to the base and configured to rotate about a yaw axis and a second portion rotatably secured to the first portion and configured to rotate about a pitch axis. Each sensor or light source is secured to one of the fixtures and is configured to direct light at yaw and pitch angles relative to the base.

Abstract: A high-speed method and system for inspecting and sorting a stream of unidentified mixed parts are provided. The system includes a pair of inspection stations each of which includes a vision-based robotic subsystem including a robot configured to pick up a self-supporting part and place the part on a fixtureless rotary stage. A second subsystem optically measures a profile and features of the part during part rotation. A processor is operable to compare the profile and features of the part with the profile and corresponding features of stored templates to identify a matching template. A mechanism including a part sorter directs unidentified parts and parts having an unacceptable geometric dimension or defect to a reject part area and directs identified parts having acceptable geometrical dimensions and no significant defects to good part areas.

Abstract: A sorting system for inspected parts includes a storage assembly, a conveyance system, and a controller. The storage assembly has a plurality of bins configured to receive and store the inspected parts. The conveyance system is configured to deliver the inspected parts to the storage assembly. The controller programmed to, assign part types to each of the plurality of bins. The controller is further programmed to operate the conveyance system to deliver each of the inspected parts to one of the plurality of bins having a matching part type. The controller is further programmed to, in response to a full condition of the storage assembly, empty the inspected parts from a first the plurality of bins.

Abstract: An inspection system includes a base plate, an array of fixtures, a plurality of light sources, and a drive mechanism. Each fixture has a first portion rotatably secured to the base plate and configured to rotate about a yaw axis and a second portion rotatably secured to the first portion and configured to rotate about a pitch axis. Each light source is secured to one of the fixtures and is configured to direct light at yaw and pitch angles relative to the base plate. The drive mechanism is configured to rotate the first portions of each fixture about each respective yaw axis and to rotate the second portions of each fixture about each respective pitch axis to adjust yaw and pitch angles of each light source, respectively.

Abstract: A method and system for inspecting unidentified mixed parts to identify the parts are provided. The system includes an inspection station which includes a vision-based robotic subsystem including a robot configured to pick up a self-supporting part and place the part on a fixtureless rotary stage so that a part axis of the part is substantially centered and aligned with a measurement axis of the inspection station during part rotation. A second subsystem optically measures a profile and features of the self-supporting part during part rotation. A processor is operable to compare the profile and the features of the part to be identified with the profile and corresponding features of stored templates to identify a template which matches the profile and features of the part to be identified and to generate and transmit an identification signal representing a part identification code for the part associated with a matched template.

Abstract: A computer-implemented method of automatically generating inspection templates of a plurality of known good fasteners to identify fasteners at an inspection station is provided. The method includes providing a data entry mechanism to provide content needed to identify a plurality of unidentified mixed fasteners. The method also includes storing the content in a database, extracting the content from the database and creating the inspection templates from the extracted content. Each of the templates including a fastener profile and a set of features. Each of the features includes a range of acceptable values. Each of the templates has a fastener identification code associated therewith.

Abstract: A high-speed method and system for inspecting and sorting a stream of unidentified mixed parts are provided. The system includes a pair of inspection stations each of which includes a vision-based robotic subsystem including a robot configured to pick up a self-supporting part and place the part on a fixtureless rotary stage. A second subsystem optically measures a profile and features of the part during part rotation. A processor is operable to compare the profile and features of the part with the profile and corresponding features of stored templates to identify a matching template. A mechanism including a part sorter directs unidentified parts and parts having an unacceptable geometric dimension or defect to a reject part area and directs identified parts having acceptable geometrical dimensions and no significant defects to good part areas.

Abstract: A method and system for inspecting unidentified mixed parts to identify the parts are provided. The system includes an inspection station which includes a vision-based robotic subsystem including a robot configured to pick up a self-supporting part and place the part on a fixtureless rotary stage so that a part axis of the part is substantially centered and aligned with a measurement axis of the inspection station during part rotation. A second subsystem optically measures a profile and features of the self-supporting part during part rotation. A processor is operable to compare the profile and the features of the part to be identified with the profile and corresponding features of stored templates to identify a template which matches the profile and features of the part to be identified and to generate and transmit an identification signal representing a part identification code for the part associated with a matched template.

Abstract: A high-speed, 3-D method and system for optically inspecting parts are provided. The system includes a part transfer subsystem including a transfer mechanism adapted to support a part at a loading station and transfer the supported part from the loading station to an inspection station at which the part has a predetermined position and orientation for inspection. The system also includes an illumination assembly to simultaneously illuminate an end surface of the part and a peripheral surface of the part. The system further includes a lens and detector assembly to form an optical image of the illuminated end surface and an optical image of the illuminated peripheral surface of the part and to detect the optical images. The system still further includes a processor to process the detected optical images to obtain an end view of the part and a 3-D panoramic view of the peripheral surface of the part.

Abstract: A high-speed method and system for inspecting a stream of parts using at least one transparent traveling carrier of a conveyor subsystem are provided. The subsystem has a forward reach and a return reach. The method includes controllably receiving a stream of parts in rapid succession on the at least one traveling carrier and utilizing the subsystem to transfer the stream of parts in rapid succession to a part inspection station. The bottom surface of each part is illuminated through its traveling carrier with radiant energy when the part is located at the inspection station to generate reflected radiation signals which travel through its traveling carrier. A bottom image of each illuminated bottom surface is formed from the reflected radiation signals at an imaging location between the forward and return reaches at the inspection station. The bottom images are detected at the imaging location.

Abstract: Method and system for inspecting a manufactured part supported on an optically-transparent window of a rotary actuator at an inspection station are provided. The window rotatably supports the part in a generally vertical orientation at which a bottom end surface of the part has a position and orientation for optical inspection. An illuminator is configured to illuminate the bottom end surface of the part through the window with radiant energy to obtain reflected radiation signals which are reflected off the bottom end surface of the part. The reflected radiation signals travel through the window. A lens and detector assembly is configured to form a bottom image from the reflected radiation signals at a bottom imaging location below the window and is configured to detect the bottom image. The window is made of a material which is substantially transparent to the radiant energy and the reflected radiation signals.

Abstract: A high-speed method and system for inspecting a stream of parts using at least one transparent traveling carrier of a conveyor subsystem are provided. The subsystem has a forward reach and a return reach. The method includes controllably receiving a stream of parts in rapid succession on the at least one traveling carrier and utilizing the subsystem to transfer the stream of parts in rapid succession to a part inspection station. The bottom surface of each part is illuminated through its traveling carrier with radiant energy when the part is located at the inspection station to generate reflected radiation signals which travel through its traveling carrier. A bottom image of each illuminated bottom surface is formed from the reflected radiation signals at an imaging location between the forward and return reaches at the inspection station. The bottom images are detected at the imaging location.

Abstract: A high-resolution imaging and processing method and system for determining a geometric dimension of a part is provided. The method includes directing at least one plane of collimated radiation at a surface of a supported part. Each of the planes is occluded by the part to create unobstructed first and second planar portions of the plane of radiation passing by and not blocked by the supported part and to cast a radiation shadow of the supported part. Each of the first and second planar portions has a width and contains an amount of radiation which is representative of a respective geometric dimension of the part to be determined. The method includes increasing the width and decreasing the intensity of the first and second planar portions imaged on first and second predetermined measuring areas, respectively.

Abstract: A high-resolution imaging and processing method and system for increasing the range of a geometric dimension of a part that can be determined are provided. The method includes directing at least one plane of collimated radiation at a surface of the part. Each of the planes is occluded by the part to create unobstructed first and second planar portions of the plane of radiation. Each of the first and second planar portions has a width and contains an amount of radiation which is representative of a respective geometric dimension of the supported part to be determined. The method includes increasing the width and decreasing the intensity of the first and second planar portions imaged on a plurality of predetermined measuring areas to obtain respective elongated planar portions and to produce respective electrical signals. The electrical signals are processed to determine the geometric dimension with enhanced accuracy.

Abstract: A high-speed, high-resolution, triangulation-based, 3-D method and system for inspecting manufactured parts and sorting the inspected parts are provided. The method includes consecutively transferring the parts so that the parts move along a path which extends from a supply of parts and through an imaging station. A triangulation-based sensor head is supported at the imaging station. The sensor head is configured to generate focused lines of radiation and to sense corresponding reflected lines of radiation. The focused lines are delivered onto an end surface of each part to obtain a corresponding array of reflected lines of radiation. The sensor head senses the array of reflected lines to obtain a corresponding set of 2-D profile signals. The set of profile signals represent a 3-D view of the end surface. The set of 2-D profile signals of each part is processed to identify parts having an unacceptable defect.