Abstract: A stream calibration arrangement for visually determining the position and orientation of a sprayed material stream. Use of a stream calibration fixture to determine adjustments to an adjustable spray gun mount to realign a spray stream without altering the taught path of a robot carrying the spray gun. Alternatively, the stream is realigned by altering the taught robot path and requiring no gun mount adjustment. Stream realignment is also carried out automatically with and without gun mount adjustments. Machine vision is used for automatic stream realignment.

Abstract: A three-dimensional optical measurement system, where it is desired to move the light beam or plane to more than one position to increase the amount of data acquired. A rotating disk is provided with segments of lenses, zone plates or other rotationally invariant grating patterns on it. The beam or plane is passed through the segments as the disk rotates and is deflected to predetermined angles. The accurate repeatability of this arrangement allows the use of calibration data and encoding of the light planes for ambiguity resolution to provide an accurate measurement system. Diverging beam light sources are readily accommodated. Similarly translating frames with segments of translationally invariant lenses or grating patterns may be used. Two-dimensional holographic gratings may be used to generate raster scans.

Abstract: An arrangement in which three-dimensional surface measurements are obtained by projecting a non-planar light beam on a surface and interpreting the image by triangulation. The non-planar beam makes it possible to determine its angle of incidence with the surface in an unambiguous manner, and allows surrounding a manufacturing process to provide continuous data when guiding the process around corners. A non-planar reflecting surface or other arrangement is used to generate the non-planar light beam from a planar light source. A flying spot of light may also be used. After the non-planar beam has been generated, it is projected upon the surface to be measured and forms there an intersection of the beam with the surface.

Abstract: Arrangements for detecting the presence of an opaque object in an area, such as a person in a robotic work cell. Multiple light sources, light reflecting surfaces, light boxes with hole patterns or fiber optic light sources are spaced around the perimeter of the area and imaged by a camera. The change of the camera signal from its normal condition is used to interrupt power to safeguard personnel and/or machinery.

Abstract: A method and arrangement for enhancing the ability of robots to perform precision assembly and machining employing adaptive clamping surfaces attached to the robot end effector in locations providing high mechanical advantage against working forces, and adaptive clamping foundations that become immobilized at the desired work location to form a local work foundation.

Abstract: Two embodiments for enhancing the detection of a selected area on a surface that may produce specular reflection. In the first embodiment the selected area is coated with a material which will only reflect incident radiation over a narrow band of frequencies and the surface is irradiated with a broadband radiation source that includes the reflectance band of the coating. The irradiated surface is imaged on an imaging device such as a TV camera through a filter selected to reject all but the narrow band of frequencies reflected from the selected area. Further enhancement is provided by comparing the results with those from the same signals filtered by a filter that is the complement of the first. Standard signal processing can then be applied.

Abstract: An arrangement in robot-controlled systems using vision devices for sensing visual or optical characteristics of predetermined parameters associated with the robot-controlled system or the process carried out by the system. A flexible barrier is placed between the vision device and visually interfering effects resulting from the robot-controlled process, such as bright light of a welding arc, or particles such as smoke or machining chips. The flexible barrier provides an economical solution for accommodating complex shapes and imprecise positioning.

Abstract: An arrangement for improved dispensed material bead profile control, in which a viscous material is dispensed in a stream upon a surface. The stream is transported along that surface and forms a bead of the viscous material. The bead is then confined with air streams which also reshape the profile of the bead. The material is dispensed by a nozzle which has at least two orifices in its proximity. One orifice is located at a distance from the nozzle which is greater than for the other orifice. The orifices form air streams under pressure and direct the air streams toward the material stream, as well as toward the bead formed on the surface when the material stream is transported along that surface.

Abstract: An optical spot scanning system for use in three dimensional measurement and inspection of an object surface wherein a deflector means is placed in the path of the projection axis of the spot projector to deflect the portion of same between the deflector and the object surface, thereby moving the spot to various positions on the object surface, and wherein the deflector means is also positioned in the path of the optical axis of the system sensing means to deflect the portion of same between the sensing means and the object surface by the same degree as the portion of the projection axis is deflected, thereby ensuring the axes portions which are aligned to be coplanar remain coplanar, and that the image of the spot on the object surface will be properly conveyed to the linear sensor array in the sensing means.

Abstract: A 3-D measurement system utilizing a holographic scanner is provided with beam direction compensation means for compensating for changes in angular deflection of the scanner and further means is provided for synchronizing the scanner diffraction segments with the camera imaging mechanism of the 3-D system as well as for providing multiple offsets of the projected beam.

Abstract: An arrangement for aligning a first object relative to a second object, in which a light pattern is projected from the first object onto the second object. An image of the pattern on the second object is recorded with a camera mounted on the first object. From the camera image it is possible to determine the relative position and orientation of the second object relative to the first object. In an alternate arrangement, a first light pattern is projected from the first object onto the second object, and a second light pattern is projected from the first object onto the second object, so that the second patten and the first pattern form a uniquely identifiable overlap pattern when the second object is in predetermined alignment with respect to the first object. From a camera image which has recorded the overlapping patterns, the position and orientation of the second object may be determined relative to the first object.

Abstract: An arrangement for controlling the flow of fluid in which the fluid is allowed to flow through a selected number of parallel paths of various flow capacities as determined by restricting orifices and cutoff valves. Accurate volume/length of fluid is dispensed at variable velocities by controlling both applicator velocity and flow rate. An arrangement is also provided for controlling the shape of the deposited fluid employing controlled air flow confinement.

Abstract: An arrangement for scanning the measurement field of view of a three-dimensional measurement system, in which the measurement system is pivoted through a relatively small motion to scan a relatively large area of volume. The measurement system is rotated via a control unit which accurately controls the rotation. Mathematical corrections are applied to determine the true measured coordinates.

Abstract: An arrangement for 3-D optical measurement systems employing scanned light beams or planes. A lens used to image projected light that is reflected from a measured surface, is moved onto a light-sensitive detector. The lens movement is coordinated with the movement of the projected light beam or plane to assure that the image on the detector remains in sharp focus at all times. The sharp focus is maintained by moving the detector in coordination with the movement of the projected light beam or plane, or by changing the effective optical path lengths to the detector in coordination with the movement of the projected light beam or plane.

Abstract: An arrangement in which three-dimensional measurement sensors are calibrated using linear translation of three flat plates, one orthogonal to the path, one sloping vertically, one sloping horizontally. Sensors for which linear interpolation applies need only calibrate two surfaces of the sensor volume for complete calibration. Two flat surfaces are adequate for calibrating a volume if one surface is used twice.

Abstract: A pattern of light is projected upon a surface to be measured which may be devoid of surface detail. A sharply focused image of the surface provides distance discrimination. Although the projected pattern may be separate from the imaging optics, a common optics path removes distortion, provides maximum sensitivity and eliminates processing for misalignment between projector and imager. Sequential cross-correlation, synchronous detection or percent modulation processing methods may be readily implemented to develop three-dimensional coordinates relative to the sensor for all in-focus regions of the image. Refocusing the lens provides depth coverage. The amount of data can be increased by adapting the projected pattern to produce a maximum of detail in the direction of minimum rate of change of depth of the surface being measured.

Abstract: An arrangement for scanning the measurement field of view of an optical measurement system, in which one or more reflecting surfaces are placed within the optical path(s) of an optical measurement system. The reflecting surface is rotated and/or translated through a control unit which controls accurately the rotating and/or translating motion. Mathematical corrections are applied to determine the true measured coordinates. The view direction of the optical measurement system is diverted by the reflecting surface mounted on a precision mechanism for scanning the view in a controlled manner.

Abstract: Arrangements for detecting the presence of an opaque object in an area, such as a person in a robotic work cell. Multiple light sources, light reflecting surfaces, light boxes with hole patterns or fiber optic light sources are spaced around the perimeter of the area and imaged by a camera. The change of the camera signal from its normal condition is used to interrupt power to safeguard personnel and/or machinery.

Abstract: Methods are provided for reducing the number of projected patterns required to make two- or three-dimensional surface measurements on a sub-class of surfaces comprising relatively smooth surfaces. By including apriori knowledge about the surface to be measured, pattern ambiguities can be resolved by processing rather than by additional projected patterns.

Abstract: Three-dimensional surface measurements are made in the presence of interfering background light such as weld arc glare by scanning the surface with a narrow light beam and synchronously masking the image of the illuminated surface to block all light within the area of expected light returned by the surface from the scanned light beam. The masking is moved synchronously across the image area as the expected returned light follows the scanned path of the scanning light beam. Masking is accomplished mechanically or by electro-optic devices.