Method and apparatus for utilizing wheel profile data during wheel assembly service procedures

• US 10,013,754 B2
• Filed: 08/08/2014
• Issued: 07/03/2018
• Est. Priority Date: 08/09/2013
• Status: Active Grant

• Current Assignee: Hunter Engineering Company
• Original Assignee: Hunter Engineering Company
• Inventors: Douglas, Michael W., Reynolds, Sean D., Meyer, Gregory F., Dorrance, Daniel R.
• Primary Examiner(s): Senfi, Behrooz
• Assistant Examiner(s): WALSH, KATHLEEN M.
• Application Number:
  US14/455,564
• Publication Number:
  US 20150042787A1
• Time in Patent Office: 1,425 Days
• Field of Search: 348 95, 348148
• CPC Class Codes: G01B 11/2513 with several lines being projected in more than one direction, e.g. grids, patterns
• CPC Class Codes: G01M 1/326 the body being a vehicle wheel
• CPC Class Codes: G01M 11/081 by using a contact-less detection method, i.e. with a camera
• CPC Class Codes: G01M 17/013 Wheels
• CPC Class Codes: G06T 2207/10028 Range image; Depth image; 3D point clouds
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: G06T 7/0008 checking presence/absence

Abstract

Methods and apparatus for utilizing vehicle wheel assembly surface profile data acquired by a vehicle wheel service system from a non-contact imaging sensor and a projected pattern of optically distinct elements on the vehicle wheel assembly surface to identify one or more features of the vehicle wheel assembly, to receive operator input, and to facilitate the placement of imbalance correction weights onto the vehicle wheel assembly surface.

Claims

1. A service system for a vehicle wheel assembly having an inner surface and an outer surface, the service system comprising:

a spindle shaft configured to receive the vehicle wheel assembly for rotation about an axis;

at least one source of optical energy configured to project at least one pattern of light defining a plurality of non-continuous discrete optically detectable elements towards the inner surface or the outer surface of the wheel assembly;

an imaging sensor configured to acquire a plurality of images of the plurality of non-continuous discrete optically detectable elements projected on the wheel assembly surface, at least two of said images acquired at different rotational orientations of the wheel assembly as the vehicle wheel assembly is rotated about said axis; and

a processor configured with program instructions to;

a) determine spatial positions for at least two of the plurality of non-continuous discrete optically detectable elements on the wheel assembly surface from at least two of the acquired images;

b) determine a plurality of axial profiles associated with the wheel assembly surface based on the determined spatial positions from the acquired images;

c) determine a representative axial profile associated with at least a portion of the wheel assembly based on the determined plurality of axial profiles; and

d) identify at least one observed feature of the wheel assembly using contour elements present in at least one determined axial profile representing a displacement of the wheel assembly surface from said representative profile.

2. A system in accordance with claim 1 wherein said feature is at least one of an index marker, an installed valve stem, a wheel spoke, a valve stem receiving bore, a bolt hole, surface-adhered material, or wheel rim surface damage.

3. A system in accordance with claim 1 wherein said feature is an installed imbalance correction weight;

and

wherein said processor is further configured with program instructions to identify from determined plurality of axial profiles at least one characteristic of said installed imbalance correction weight, said characteristic selected from a set of characteristics including a placement position on said wheel assembly, a placement orientation on said wheel assembly, spatial dimensions, and a weight style.

4. A system in accordance with claim 1 wherein said identified observed feature is an observed axial position along said spindle shaft, of a hub face of the vehicle wheel assembly relative to an observed axial position along said spindle shaft, of at least one rim edge of the vehicle wheel assembly;

wherein said processor is further configured with program instructions to identify a reverse axial mounting orientation of said vehicle wheel assembly on said spindle shaft from said identified observed feature; and

wherein an outside hub face of the wheel assembly is disposed axially closer to the balancer than an inside hub face of the wheel assembly.

5. A service system for a vehicle wheel assembly having an inner surface and an outer surface, the service system comprising:

a spindle shaft configured to receive the vehicle wheel assembly for rotation about an axis;

at least one source of optical energy configured to project at least one pattern of light defining a plurality of discrete optically detectable elements towards the inner surface or the outer surface of the wheel assembly;

an imaging sensor configured to acquire a plurality of images of the plurality of discrete optically detectable elements projected on the wheel assembly surface, each image acquired at a different rotational orientation of the wheel assembly as the vehicle wheel assembly is rotated about said axis of rotation of the spindle shaft;

a processor configured with program instructions to;

determine a spatial position of at least two of the plurality of non-continuous discrete optically detectable elements from each of the acquired images;

determine a plurality of profiles associated with the wheel assembly based on the determined spatial positions from each of the acquired images; and

determine, as a characteristic of the wheel assembly, a representation of observed runout present in the wheel assembly surface at a selected rotational position, using contour elements present in the plurality of determined profiles to establish an average profile, and wherein said observed runout is represented by a displacement of the wheel assembly surface at said selected rotational position from said average profile.

6. A system in accordance with claim 5 wherein said wheel assembly surface is a circumferential surface of the vehicle wheel assembly selected from a set of circumferential surfaces including an inner rim edge, an outer rim edge, an inner bead seat, an outer bead seat, a tire surface, or an imbalance correction weight placement surface.

7. A system in accordance with claim 5 wherein said representation of runout is a representation of an axial runout and/or a radial runout present in the wheel assembly surface.

8. A system in accordance with claim 5 wherein said processor is further configured with program instructions to compare a first determined representation of runout with a second determined representation of runout to identify a change in at least one of a phase and a magnitude there between, said change representative of a change in mounting of the vehicle wheel assembly on the spindle shaft having occurred between said first and second determinations of runout.

9. A method for operating a vehicle wheel service system including a spindle shaft for receiving a vehicle wheel assembly for rotation about an axis, comprising:

projecting, from at least one source of optical energy, at least one pattern of light including a plurality of non-continuous discrete optically detectable elements, towards a spatial region expected to contain a surface of a vehicle wheel assembly mounted to the spindle shaft;

acquiring, with an imaging sensor, a plurality of images of the spatial region, at least two of said images acquired at different rotational orientations of the wheel assembly as the wheel assembly is rotated about said axis;

evaluating at least two of said acquired images, by

identifying at least two of said plurality of non-continuous discrete optically detectable elements within said acquired image;

determining spatial positions for said identified non-continuous discrete optically detectable elements; and

determining a surface profile of the wheel assembly based on the determined spatial positions;

comparing a set of said determined surface profiles of the wheel assembly to detect at least one non-circumferential contour feature on the wheel assembly surface; and

identifying at least one observed feature of the wheel assembly directly from at least one detected non-circumferential contour feature present within the set of determined surface profiles.

14. The method of claim 9 wherein said at least one observed feature is at least one of, a location of a valve stem receiving bore, a bolt hole, a surface-adhered material, or wheel rim damage.

15. The method of claim 9 wherein said at least one observed feature is an installed imbalance correction weight on said wheel assembly surface;

and

further including the step of identifying from said at least one detected non-circumferential contour feature present within the set of determined profiles, at least one characteristic of said installed imbalance correction weight, said characteristic selected from a set of characteristics including a spatial dimension of said installed imbalance correction weight, an amount of said installed imbalance correction weight, and a style of said installed imbalance correction weight.

16. The method of claim 9 wherein an initial profile of said wheel assembly surface is established from said set of said determined surface profiles in response to an absence of any detected non-circumferential contour features;

wherein said steps of projecting, acquiring, evaluating and comparing are repeated at least once following establishment of said initial profile;

wherein responsive to a detection of at least one non-circumferential contour feature on the wheel assembly surface following establishment of said initial profile, interpreting said non-circumferential contour feature as an indicator object, and an axial position of said indicator object relative to said initial profile and as an operator input.

20. The method of claim 16 wherein said axial position and said operator input identifies an imbalance correction weight placement plane of said vehicle wheel assembly;

and

further including the step of calculating at least one imbalance correction weight characteristic and residual imbalance value associated with the vehicle wheel assembly in response to said identification of said imbalance correction weight placement plane.

10. A method for operating a vehicle wheel service system including a spindle shaft for receiving a vehicle wheel assembly for rotation about an axis, comprising:

projecting, from at least one source of optical energy, at least one pattern of light including a plurality of discrete optically detectable elements, towards a spatial region expected to contain a surface of a vehicle wheel assembly mounted to the spindle shaft;

acquiring, with an imaging sensor, at least one image of the spatial region;

evaluating the acquired image, by

identifying said plurality of discrete optically detectable elements within said acquired image;

determining spatial positions for said identified discrete optically detectable elements; and

determining a surface profile based on the determined spatial positions;

wherein said steps of acquiring and evaluating are repeated at least once for a plurality of images each obtained at a different rotational orientation of the vehicle wheel assembly as the vehicle wheel assembly rotates about the spindle axis of rotation;

identifying a measurement of an observed runout of a surface of a vehicle wheel assembly from contour features present in a plurality of determined profiles; and

further including the step of providing a representation of said observed runout present in said surface at a selected rotational position utilizing said plurality of determined profiles to establish an average profile, and wherein said observed runout is represented by a displacement of the wheel assembly surface at said selected rotational position from said average profile.

11. The method of claim 10 wherein said surface of the vehicle wheel assembly is a circumferential feature of the vehicle wheel assembly selected from a set of circumferential features including an inner rim edge, an outer rim edge, an inner bead seat, an outer bead seat, a tire surface, or an imbalance correction weight placement surface.

12. The method of claim 10 wherein said representation of observed runout is a representation of an axial runout and/or a radial runout of said surface of the vehicle wheel assembly.

13. The method of claim 10 wherein said representation of observed runout is identified at least twice for a vehicle wheel assembly;

wherein said representations of said observed runout are compared with each other to identify any changes in at least one of a magnitude or a phase there between; and

wherein said changes in said magnitude and/or phase of said observed runout of the vehicle wheel assembly are indicative of a change in a mounting of said vehicle wheel assembly on said shaft.

17. A method for operating a vehicle wheel service system including a spindle shaft for receiving a vehicle wheel assembly for rotation about an axis, comprising:

projecting a pattern of optical energy containing a plurality of discrete elements towards a spatial region expected to contain a surface of a vehicle wheel assembly mounted to the spindle shaft;

acquiring, with an imaging sensor, at least one image of the spatial region, said image including optical energy reflected from said surface of a vehicle wheel assembly present within said spatial region;

evaluating the acquired image to determine a surface profile associated with said reflected optical energy;

identifying, from contour elements present in the determined profile, an initial profile of a rim surface of the vehicle wheel assembly onto which said optical energy is projected;

repeating the steps of projecting, acquiring, and evaluating at least once to identify at least one current profile of the vehicle wheel assembly rim surface;

detecting a change in a portion of said at least one current profile from said initial profile resulting from a placement of an indicator object between a source of said optical energy and said rim surface;

interpreting said change as an axial position of said indicator object relative to said determined initial profile, and as an operator input;

controlling said at least one source of optical energy to provide visual guidance for placement of an imbalance correction weight onto said vehicle wheel assembly rim surface in response to said interpreted axial position differing from a selected imbalance correction weight placement plane.

18. A method for operating a vehicle wheel service system including a spindle shaft for receiving a vehicle wheel assembly for rotation about an axis, comprising:

projecting a pattern of optical energy containing a plurality of discrete elements towards a spatial region expected to contain a surface of a vehicle wheel assembly mounted to the spindle shaft;

acquiring, with an imaging sensor, at least one image of the spatial region, said image including optical energy reflected from said surface of a vehicle wheel assembly present within said spatial region;

evaluating the acquired image to determine a surface profile associated with said reflected optical energy; and

identifying, from contour elements present in the determined profile, a surface contour of a wheel assembly rim suitable for attachment of an imbalance correction weight; and

further including the steps of;

measuring an imbalance associated with the vehicle wheel assembly;

identifying at least one imbalance correction weight and an associated placement location on said vehicle wheel assembly based on said measured imbalance and said rim surface contour;

activating said source of optical energy to illuminate a region on said rim surface;

rotationally positioning said vehicle wheel assembly such that said associated placement location for said at least one identified imbalance correction weight intersects said illuminated region;

observing said illuminated region with said imaging sensor and evaluating one or more resulting images to detect the presence of an object which is in proximity to, or placed on, said rim surface, and at least partially within said illuminated region;

wherein said step of identifying at least one imbalance correction weight further identifies at least a second imbalance correction weight and a second associated placement location on said vehicle wheel assembly based on said measured imbalance and said identified rim surface contour;

wherein said object is a first installed imbalance correction weight; and

responsive to said first installed imbalance correction weight detected at a location which is spaced from said identified associated placement location by more than a tolerance, further including the step of altering at least one of said identified second imbalance correction weight and said identified second associated placement location to achieve an imbalance goal for the vehicle wheel assembly.

19. A method for operating a vehicle wheel service system including a spindle shaft for receiving a vehicle wheel assembly for rotation about an axis, comprising:

projecting, from at least one source of optical energy, at least one pattern of light including a plurality of non-continuous discrete optically detectable elements, towards a spatial volume expected to contain a surface of a vehicle wheel assembly mounted to the spindle shaft;

acquiring, with an imaging sensor, at least one image of the spatial volume;

evaluating the acquired image, by

identifying at least two of said plurality of non-continuous discrete optically detectable elements within said acquired image;

determining, using at least one optical trait of said pattern of light, spatial positions for said identified non-continuous discrete optically detectable elements; and

detecting an absence of a vehicle wheel assembly from said spindle shaft in response to said determined spatial positions for said identified non-continuous optically detectable elements corresponding to surfaces within said spatial volume occluded from a field of view of said imaging sensor by a presence of a vehicle wheel assembly on said spindle shaft.