Patents by Inventor Aaron S. Wallack

Aaron S. Wallack has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10812778
    Abstract: This invention provides a system and method for concurrently (i.e. non-serially) calibrating a plurality of 3D sensors to provide therefrom a single FOV in a vision system that allows for straightforward setup using a series of relatively straightforward steps that are supported by an intuitive graphical user interface (GUI). The system and method requires minimal data input about the scene or calibration object used to calibrate the sensors. 3D features of a stable object, typically employing one or more subobjects, are first measured by one of the image sensors, and then the feature measurements are used in a calibration in which each of the 3D sensors images a discrete one of the subobjects, resolves features thereon and computes a common coordinate space between the plurality of 3D sensors. Sensor(s) can be mounted on the arm of an encoderless robot or other conveyance and motion speed can be measured in setup.
    Type: Grant
    Filed: August 9, 2016
    Date of Patent: October 20, 2020
    Assignee: Cognex Corporation
    Inventors: Ruibing Wang, Aaron S. Wallack, David J. Michael, Hongwei Zhu
  • Patent number: 10775160
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Grant
    Filed: August 6, 2018
    Date of Patent: September 15, 2020
    Assignee: Cognex Corporation
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Patent number: 10757394
    Abstract: This invention provides a system and method for concurrently (i.e. non-serially) calibrating a plurality of 3D sensors to provide therefrom a single FOV in a vision system that allows for straightforward setup using a series of relatively straightforward steps that are supported by an intuitive graphical user interface (GUI). The system and method requires minimal input significant data about the imaged scene or calibration object used to calibrate the sensors, thereby effecting a substantially “automatic” calibration procedure. 3D features of a stable object, typically employing a plurality of 3D subobjects are first measured by one of the plurality of image sensors, and then the feature measurements are used in a calibration in which each of the 3D sensors images a discrete one of the subobjects, resolves features thereon and computes a common coordinate space between the plurality of 3D sensors. Laser displacement sensors and a conveyor/motion stage can be employed.
    Type: Grant
    Filed: November 9, 2015
    Date of Patent: August 25, 2020
    Assignee: Cognex Corporation
    Inventors: Ruibing Wang, Aaron S. Wallack, David J. Michael, Hongwei Zhu
  • Patent number: 10482621
    Abstract: This invention provides a system and method for estimating match of a 3D alignment pose of a runtime 3D point cloud relative to a trained model 3D point cloud. It includes scoring a match of a candidate pose of the runtime 3D point cloud relative to the trained model 3D point cloud, including a visibility check that comprises (a) receiving a 3D camera optical center (b) receiving the trained model 3D point cloud; (c) receiving the runtime 3D point cloud; and (d) constructing a plurality of line segments from the optical center to a plurality of 3D points in the 3D point cloud at the runtime candidate pose. A system and method for determining an accurate representation of a 3D imaged object by omitting spurious points from a composite point cloud based on the presence or absence of such points in a given number of point clouds is also provided.
    Type: Grant
    Filed: July 20, 2017
    Date of Patent: November 19, 2019
    Assignee: COGNEX CORPORATION
    Inventors: Andrew Hoelscher, Aaron S. Wallack, Adam Wagman, David J. Michael, Hongjun Jia
  • Patent number: 10438036
    Abstract: This invention provides a system and method for reading and decoding ID features located on a surface of a curved, sloped and/or annular object, such as a tire moving on a conveyor. A plurality of 3D sensors are operatively connected to a vision system processor. The sensors are calibrated by calibration parameters to generate a stitched-together 3D image of a field of view in a common coordinate space. A motion conveyance (e.g. a conveyor) causes the object and the 3D sensors to move in relative motion, and the conveyance provides motion information to the vision system processor. An ID finder locates ID features within a version of the 3D image and a decoder (e.g. an OCR reader) generates data from the ID features. The ID finder can locate a trained portion of the ID and the search for variable code elements at a known orientation relative to the trained portion.
    Type: Grant
    Filed: November 9, 2016
    Date of Patent: October 8, 2019
    Assignee: Cognex Corporation
    Inventors: Matthew R. Reome, Ali M. Zadeh, Robert A. Wolff, Ruibing Wang, Aaron S. Wallack, David J. Michael, Hongwei Zhu, Benjamin D. Klass
  • Patent number: 10421189
    Abstract: A system and method for robustly calibrating a vision system and a robot is provided. The system and method enables a plurality of cameras to be calibrated into a robot base coordinate system to enable a machine vision/robot control system to accurately identify the location of objects of interest within robot base coordinates.
    Type: Grant
    Filed: October 23, 2015
    Date of Patent: September 24, 2019
    Assignee: Cognex Corporation
    Inventors: Aaron S. Wallack, Lifeng Liu, Xiangyun Ye
  • Publication number: 20190265027
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Application
    Filed: August 6, 2018
    Publication date: August 29, 2019
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Publication number: 20190084160
    Abstract: A system and method for robustly calibrating a vision system and a robot is provided. The system and method enables a plurality of cameras to be calibrated into a robot base coordinate system to enable a machine vision/robot control system to accurately identify the location of objects of interest within robot base coordinates.
    Type: Application
    Filed: November 15, 2018
    Publication date: March 21, 2019
    Inventors: Aaron S. Wallack, Lifeng Liu, Xiangyun Ye
  • Publication number: 20180374239
    Abstract: This invention provides an easy-to-manufacture, easy-to-analyze calibration object which combines measurable and repeatable, but not necessarily accurate, 3D features—such as a two-sided calibration object/target in (e.g.) the form of a frustum, with a pair of accurate and measurable features, more particularly parallel faces separated by a precise specified thickness, so as to provide for simple field calibration of opposite-facing DS sensors. Illustratively, a composite calibration object can be constructed, which includes the two-sided frustum that has been sandblasted and anodized (to provide measurable, repeatable features), with a flange whose above/below parallel surfaces have been ground to a precise specified thickness. The 3D corner positions of the two-sided frustum are used to calibrate the two sensors in X and Y, but cannot establish absolute Z without accurate information about the thickness of the two-sided frustum; the flange provides the absolute Z information.
    Type: Application
    Filed: October 13, 2017
    Publication date: December 27, 2018
    Inventors: Aaron S. Wallack, Robert A. Wolff, David J. Michael, Ruibing Wang, Hongwei Zhu
  • Patent number: 10041786
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Grant
    Filed: March 13, 2017
    Date of Patent: August 7, 2018
    Assignee: Cognex Corporation
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Publication number: 20180130224
    Abstract: This invention provides a system and method for estimating match of a 3D alignment pose of a runtime 3D point cloud relative to a trained model 3D point cloud. It includes scoring a match of a candidate pose of the runtime 3D point cloud relative to the trained model 3D point cloud, including a visibility check that comprises (a) receiving a 3D camera optical center (b) receiving the trained model 3D point cloud; (c) receiving the runtime 3D point cloud; and (d) constructing a plurality of line segments from the optical center to a plurality of 3D points in the 3D point cloud at the runtime candidate pose. A system and method for determining an accurate representation of a 3D imaged object by omitting spurious points from a composite point cloud based on the presence or absence of such points in a given number of point clouds is also provided.
    Type: Application
    Filed: July 20, 2017
    Publication date: May 10, 2018
    Inventors: Andrew Hoelscher, Aaron S. Wallack, Adam Wagman, David J. Michael, Hongjun Jia
  • Publication number: 20170299380
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Application
    Filed: March 13, 2017
    Publication date: October 19, 2017
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Patent number: 9734419
    Abstract: This invention provides a system and method to validate the accuracy of camera calibration in a single or multiple-camera embodiment, utilizing either 2D cameras or 3D imaging sensors. It relies upon an initial calibration process that generates and stores camera calibration parameters and residual statistics based upon images of a first calibration object. A subsequent validation process (a) acquires images of the first calibration object or a second calibration object having a known pattern and dimensions; (b) extracts features of the images of the first calibration object or the second calibration object; (c) predicts positions expected of features of the first calibration object or the second calibration object using the camera calibration parameters; and (d) computes a set of discrepancies between positions of the extracted features and the predicted positions of the features.
    Type: Grant
    Filed: December 30, 2008
    Date of Patent: August 15, 2017
    Assignee: COGNEX CORPORATION
    Inventors: Xiangyun Ye, Aaron S. Wallack, Guruprasad Shivaram, Cyril C. Marrion, David Y. Li
  • Patent number: 9605950
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Grant
    Filed: January 7, 2014
    Date of Patent: March 28, 2017
    Assignee: COGNEX CORPORATION
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Patent number: 9488469
    Abstract: This invention provides a system and method for the high-accuracy measurement of an object's surface displacement at a plurality of measurement points using a laser displacement sensor and a sensor process that corrects for noise and other accuracy-reducing factors. A camera assembly with an imager and optics package acquires images of an object surface, and a laser assembly projects a line on the object surface. These tasks can include (a) defining patches of the surface based upon a grid; (b) registering the object and aligning the grid with respect to the object; (c) excluding from the analysis of the image, irregular surface features; (d) oversampling one or more patches to improve overall accuracy; (e) specifying measurement resolution (i.e. in the (x, y z) dimensions), including choosing appropriate pixel sizes and number of measurements per measurement point; and (f) selecting optimal acquisition/image formation parameters.
    Type: Grant
    Filed: April 21, 2014
    Date of Patent: November 8, 2016
    Assignee: COGNEX CORPORATION
    Inventors: David J. Michael, Aaron S. Wallack
  • Patent number: 9393694
    Abstract: A system and method for robustly calibrating a vision system and a robot is provided. The system and method enables a plurality of cameras to be calibrated into a robot base coordinate system to enable a machine vision/robot control system to accurately identify the location of objects of interest within robot base coordinates.
    Type: Grant
    Filed: May 14, 2010
    Date of Patent: July 19, 2016
    Assignee: Cognex Corporation
    Inventors: Aaron S. Wallack, Lifeng Liu, Xiangyun Ye
  • Publication number: 20160039096
    Abstract: A system and method for robustly calibrating a vision system and a robot is provided. The system and method enables a plurality of cameras to be calibrated into a robot base coordinate system to enable a machine vision/robot control system to accurately identify the location of objects of interest within robot base coordinates.
    Type: Application
    Filed: October 23, 2015
    Publication date: February 11, 2016
    Inventors: Aaron S. Wallack, Lifeng Liu, Xiangyun Ye
  • Patent number: 9124873
    Abstract: This invention provides a system and method for determining correspondence between camera assemblies in a 3D vision system implementation having a plurality of cameras arranged at different orientations with respect to a scene involving microscopic and near microscopic objects under manufacture moved by a manipulator, so as to acquire contemporaneous images of a runtime object and determine the pose of the object for the purpose of guiding manipulator motion. At least one of the camera assemblies includes a non-perspective lens. The searched 2D object features of the acquired non-perspective image, corresponding to trained object features in the non-perspective camera assembly can be combined with the searched 2D object features in images of other camera assemblies, based on their trained object features to generate a set of 3D features and thereby determine a 3D pose of the object.
    Type: Grant
    Filed: October 24, 2013
    Date of Patent: September 1, 2015
    Assignee: Cognex Corporation
    Inventors: Lifeng Liu, Aaron S. Wallack, Cyril C. Marrion, Jr., David J. Michael
  • Publication number: 20140347473
    Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.
    Type: Application
    Filed: January 7, 2014
    Publication date: November 27, 2014
    Applicant: Cognex Corporation
    Inventors: Robert A. Wolff, Michael C. Moed, Mikhail Akopyan, Robert Tremblay, Willard Foster, Aaron S. Wallack
  • Patent number: 8872911
    Abstract: A method and apparatus for assessing at least one of motion linearity of a motion stage, stage motion straightness of a motion stage, image capture repeatability of a motion stage and camera and accuracy of a calibration plate used to assess motion stage characteristics, the method including using a line scan camera to generate two dimensional images of a calibration plate having a plurality imageable features thereon, examining the images to identify actual coordinates of the imageable features and using the actual coordinates to assess linearity, straightness, repeatability and/or plate accuracy.
    Type: Grant
    Filed: January 5, 2010
    Date of Patent: October 28, 2014
    Assignee: Cognex Corporation
    Inventors: Aaron S. Wallack, David J. Michael