Abstract: An optical coordinate measuring system (OCMS) for manufactured components having build variations that require splices for accurate integration of the components. The OCMS includes manufacturing the components that include integral three dimensional optical reticle image arrays affixed to predetermined surfaces of the components, such that those surfaces can be optically captured in three dimensional composite measurements associated with various 3-D scanned poses. Each pose includes an orthogonal pair of grid lines, and each pose involves a single field of view. A plurality of poses can then be collated to form composite measurements that extend out-of-range of any single pose. The three dimensional optical reticle image arrays can be concave or convex, ideally formed as an integral part of each as-manufactured component. The three dimensional aspect enhances scanning clarity of each scanned pose, thus assuring greater accuracies of composite measurements that result from any plurality of collated poses.

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A method of determining a pose of a workpiece includes receiving known positions of a plurality of reference features of a workpiece in a first pose in a first coordinate space, determining from the known positions an estimate of the first pose of the workpiece in a second coordinate space in which any pose of the workpiece is defined by six distinct components, and at least one of the six components are known. The method includes receiving a position of a second feature of the workpiece in the second coordinate space when the workpiece is disposed in a distinct, second pose in which the at least one known components remain constant between the first and second pose. The method includes determining the second pose of the workpiece from the first pose estimate and the position of the second feature of the workpiece in the second pose.

Abstract: Systems and methods are provided for collision prevention One embodiment is an apparatus that includes a robot. The robot includes an end effector that operates within a manufacturing cell, and actuators defining a kinematic chain that reorients the end effector within the manufacturing cell. The robot also includes an imaging system mounted with the end effector, and a controller. The controller is able to direct the actuators to orient the imaging system towards the mirror, to acquire a point cloud of 3D positions by operating the imaging system to scan an image in the mirror, and to revise the 3D positions in the point cloud by folding the 3D positions about a surface defined by the mirror. The robot is also able to determine a volume occupied by the robot within the manufacturing cell, and to direct the robot to operate based on the volume to prevent collisions.

Abstract: A camera on a robotic arm end effector is used to locate a workpiece coordinate system transformation in rotation and translation with respect to the end effector coordinate system by successively measuring an offset between a target affixed to the workpiece and its expected location. The target reflects energy from a light beam provided by a light beam source. A beam splitter is used to align the light beam with a line of sight of the camera.

Abstract: A method and apparatus for cleaning a vessel. The apparatus comprises a retractable assembly and a self-propelled cleaning carriage. The retractable assembly has a center section, a first segmented arm configured to extend in a first direction from the center section in an interior of a vessel, and a second segmented arm configured to extend in a second direction from the center section in the interior of the vessel. The second direction is opposite the first direction. The self-propelled cleaning carriage surrounds at least a portion of the retractable assembly. The self-propelled cleaning carriage is configured to move along at least one of the first segmented arm or the second segmented arm.

Abstract: Systems and methods are provided for collision prevention in robot manufacturing environments. One embodiment is an apparatus that includes a robot. The robot includes an end effector that operates within a manufacturing cell, and actuators defining a kinematic chain that reorients the end effector within the manufacturing cell. The robot also includes an imaging system mounted with the end effector, and a controller that identifies a position and orientation of a mirror. The controller is able to direct the actuators to orient the imaging system towards the mirror, to acquire a point cloud of 3D positions by operating the imaging system to scan an image in the mirror, and to revise the 3D positions in the point cloud by folding the 3D positions about a surface defined by the mirror.

Abstract: A camera on a robotic arm end effector is used to locate a workpiece coordinate system transformation in rotation and translation with respect to the end effector coordinate system by successively measuring an offset between a target affixed to the workpiece and its expected location. The target reflects energy from a light beam provided by a light beam source. A beam splitter is used to align the light beam with a line of sight of the camera.

Abstract: An apparatus for measuring edge features of a work piece includes an optical sensor assembly and a reference device. The reference device includes a contact surface configured to contact a surface of the work piece adjacent to an edge of the work piece and a marked surface including a plurality of markings indicating positions relative to the contact surface. The reference device is configured to be coupled to a portion of the optical sensor assembly such that the optical sensor assembly is positioned to capture an image representing a portion of the marked surface and an edge feature of the work piece.

Abstract: A method and apparatus for cleaning a vessel. The apparatus comprises a retractable assembly and a self-propelled cleaning carriage. The retractable assembly has a center section, a first segmented arm configured to extend in a first direction from the center section in an interior of a vessel, and a second segmented arm configured to extend in a second direction from the center section in the interior of the vessel. The second direction is opposite the first direction. The self-propelled cleaning carriage surrounds at least a portion of the retractable assembly. The self-propelled cleaning carriage is configured to move along at least one of the first segmented arm or the second segmented arm.

Abstract: A method of determining a pose of a workpiece includes receiving known positions of a plurality of reference features of a workpiece in a first pose in a first coordinate space, determining from the known positions an estimate of the first pose of the workpiece in a second coordinate space in which any pose of the workpiece is defined by six distinct components, and at least one of the six components are known. The method includes receiving a position of a second feature of the workpiece in the second coordinate space when the workpiece is disposed in a distinct, second pose in which the at least one known components remain constant between the first and second pose. The method includes determining the second pose of the workpiece from the first pose estimate and the position of the second feature of the workpiece in the second pose.

Abstract: Apparatus for adaptively and interactively lighting a scene includes a digital light projector that includes a light emitter and a digital light processor optically coupled to the emitter such that the emitter light is projected onto respective individual fields of view of a field of regard illuminating the scene in accordance with a projector control signal. A camera adjacent to the projector is operative to detect light reflected or projected from the illuminated scene and generate a signal corresponding to the detected light. A signal processor coupled to the projector and the camera is operative to receive the camera signal, process the received signal into a light projector control signal in accordance with an associated set of instructions, and apply the control signal to the light projector such that the light projected onto the respective individual fields of view of the illuminating array is controlled in accordance with the instructions.

Abstract: A method and apparatus for steering energy over a wide field of view is disclosed. The apparatus comprises a beam steering system for directing a first beam from an optical source across an image plane and a WFOV optical system having the image plane, the WFOV optical system mapping the directed first beam incident on the image plane with a second beam extending angularly across the field of view. The method comprises the steps of directing a first beam from a optical source onto an image plane, optically mapping the directed first beam incident on the image plane with a second beam extending angularly across a field of view, and steering the first beam across the image plane.

Abstract: A method and apparatus for steering energy over a wide field of view is disclosed. The apparatus comprises a beam steering system for directing a first beam from an optical source across an image plane and a WFOV optical system having the image plane, the WFOV optical system mapping the directed first beam incident on the image plane with a second beam extending angularly across the field of view. The method comprises the steps of directing a first beam from a optical source onto an image plane, optically mapping the directed first beam incident on the image plane with a second beam extending angularly across a field of view, and steering the first beam across the image plane.

Abstract: Apparatus for adaptively and interactively lighting a scene includes a digital light projector that includes a light emitter and a digital light processor optically coupled to the emitter such that the emitter light is projected onto respective individual fields of view of a field of regard illuminating the scene in accordance with a projector control signal. A camera adjacent to the projector is operative to detect light reflected or projected from the illuminated scene and generate a signal corresponding to the detected light. A signal processor coupled to the projector and the camera is operative to receive the camera signal, process the received signal into a light projector control signal in accordance with an associated set of instructions, and apply the control signal to the light projector such that the light projected onto the respective individual fields of view of the illuminating array is controlled in accordance with the instructions.

Abstract: Apparatus for adaptively and interactively lighting a scene includes a digital light projector that includes a light emitter and a digital light processor optically coupled to the emitter such that the emitter light is projected onto respective individual fields of view of a field of regard illuminating the scene in accordance with a projector control signal. A camera adjacent to the projector is operative to detect light reflected or projected from the illuminated scene and generate a signal corresponding to the detected light. A signal processor coupled to the projector and the camera is operative to receive the camera signal, process the received signal into a light projector control signal in accordance with an associated set of instructions, and apply the control signal to the light projector such that the light projected onto the respective individual fields of view of the illuminating array is controlled in accordance with the instructions.

Abstract: Apparatus for adaptively and interactively lighting selected portions of a scene includes a digital light projector that includes a light emitter and a digital light processor optically coupled to the emitter such that the emitter light is projected onto respective individual fields of view of a field of regard illuminating the scene in accordance with a projector control signal. A camera adjacent to the projector is operative to detect light reflected or projected from the illuminated scene and generate a signal corresponding to the detected light. A signal processor coupled to the projector and the camera is operative to receive the camera signal, process the received signal into a light projector control signal in accordance with an associated set of instructions, and apply the control signal to the light projector such that the light projected onto the respective individual fields of view of the illuminating array is controlled in accordance with the instructions.