Imaging tool for vibration and/or misalignment analysis

• US 10,083,501 B2
• Filed: 10/24/2016
• Issued: 09/25/2018
• Est. Priority Date: 10/23/2015
• Status: Active Grant

• Current Assignee: Fluke Corporation (Fortive Corp.)
• Original Assignee: Fluke Corporation (Fortive Corp.)
• Inventors: Stuart, Michael D., Bernet, John C.
• Primary Examiner(s): Dunphy, David F
• Application Number:
  US15/332,377
• Publication Number:
  US 20170140520A1
• Time in Patent Office: 701 Days
• CPC Class Codes: G01B 11/272 using photoelectric detection means
• CPC Class Codes: G01H 9/00 Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves by using radiation-sensitive means, e.g. optical means
• CPC Class Codes: G06T 2207/10016 Video; Image sequence
• CPC Class Codes: G06T 2207/10048 Infrared image
• CPC Class Codes: G06T 2207/30164 Workpiece; Machine component
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: G06T 7/001 using an image reference approach
• CPC Class Codes: G06T 7/20 Analysis of motion motion estimation for coding, decoding, compressing or decompressing digital video signals H04N19/43, H04N19/51
• CPC Class Codes: G06T 7/246 using feature-based methods, e.g. the tracking of corners or segments
• CPC Class Codes: G06T 7/30 Determination of transform parameters for the alignment of images, i.e. image registration
• CPC Class Codes: G06T 7/70 Determining position or orientation of objects or cameras camera calibration G06T7/80

Abstract

Systems and methods can be used for analyzing image data to determine an amount of vibration and/or misalignment in an object under analysis. Image distortion present in the image data due to vibration and/or misalignment of the object during operation can be detected automatically or manually, and can be used to determine an amount of vibration and/or misalignment present. The determined amount of vibration and/or misalignment can be used to determine alignment calibration parameters for inputting into an alignment tool to facilitate alignment of the object. Various steps in determining the image distortion and/or the alignment calibration parameters can be performed using single components or can be spread across multiple components in a system.

Claims

1. A method for analyzing vibration and/or misalignment of an object comprising:

acquiring image data representative of an object while the object is in an operating state;

determining an amount of image distortion in the image due to vibration and/or misalignment of the object;

determining an amount of vibration and/or misalignment of the object based on the determined amount of image distortion, the determining the amount of vibration and/or misalignment comprising determining one or more alignment calibration parameters representative of an amount of misalignment present in the object; and

performing an alignment procedure to improve the alignment of the object based on the determined one or more alignment calibration parameters.

2. The method of claim 1, further comprising inputting the determined one or more alignment calibration parameters into an alignment tool.

3. The method of claim 2, wherein performing the alignment procedure comprises using the alignment tool.

4. The method of claim 1, further comprising, before performing the alignment procedure, stopping operation of the object.

5. The method of claim 2, wherein:

determining the one or more alignment calibration parameters representative of the amount of misalignment is performed via a processor; and

wherein

inputting the determined one or more alignment calibration parameters into the alignment tool comprises communicating the determined one or more alignment parameters from the processor to the alignment tool.

6. The method of claim 5, further comprising

determining the shape of the image distortion;

and

determining a type of misalignment of the object based on the determined shape of the image distortion; and

wherein

the determined one or more alignment calibration parameters representative of the amount of misalignment are based on the determined amount and shape of image distortion.

7. The method of claim 1, further comprising the step of presenting the acquired image data on a display;

and wherein determining an amount of image distortion in the image due to vibration and/or misalignment of the object comprises receiving, via a user interface, a selection of an area in the image data presented on the display corresponding to the image distortion.

8. The method of claim 1, wherein determining the amount of image distortion in the image due to vibration and/or misalignment of the object further comprises determining the amount of image distortion in a first direction and an amount of image distortion in a second direction different from the first.

9. A system for analyzing vibration and/or misalignment of an object comprising:

an imaging tool configured to receive radiation from a target scene and to generate image data representative of the target scene;

an alignment tool configured to assist a user in performing an alignment process; and

a processing system in communication with the imaging tool and the alignment tool, the processing system including one or more processors configured to collectively;

determine an amount of image distortion in the image data generated by the imaging tool; and

determine one or more alignment calibration parameters representative of the amount of misalignment of the object based on the determined amount of image distortion; and

wherein

the alignment tool is configured to assist the user in performing the alignment process based on the alignment calibration parameters.

10. The system of claim 9, wherein at least one processor of the processing system is located in the imaging tool such that the imaging tool is configured to determine the one or more alignment calibration parameters and communicate the one or more alignment parameters to the alignment tool.

11. The system of claim 9, wherein:

at least one processor of the processing system is located in the alignment tool;

such that

the imaging tool is configured to communicate image data to the alignment tool; and

the alignment tool is configured to determine, from the received image data, the amount of image distortion and the one or more alignment calibration parameters.

12. The system of claim 9, wherein determining the amount of image distortion in the image data comprises determining the area of the image distortion in the image data.

13. The system of claim 9, wherein the processing system is further configured to:

determine a shape of image distortion present in the image data; and

determine a type of misalignment present in the object based on the determined shape of the image distortion.

14. The system of claim 13, further comprising a user interface and a display, and wherein determining the amount and/or shape of image distortion in the image data comprises receiving an input via the user interface identifying the image distortion on the display.

15. The system of claim 13, wherein the processing system is configured to alert a user if the determined image distortion exceeds a predetermined amount.

16. The system of claim 15, wherein the processing system is in communication with a database of image distortion data, and wherein the determined amount of image distortion in the image data is compared to the database of image distortion data to determine a severity of misalignment present in the object, and, if the severity of misalignment exceeds a predetermined level, alerting the user of excessive misalignment.

17. The system of claim 16, wherein the database is stored on a remote server.

18. The system of claim 15, wherein alerting the user comprises alerting the user of a severity and/or a type of misalignment present in the object based.

19. The system of claim 9, wherein the imaging tool comprises an infrared (IR) camera module configured to receive IR radiation from a target scene and generate IR image data representative of the target scene.

20. The system of claim 19, wherein the processing system is further configured to:

determine, based on IR image data of the object, thermal growth of the object;

calculate second alignment calibration parameters for the object based on the determined thermal growth; and

wherein

the alignment tool is configured to assist the user in performing the alignment process based on the alignment calibration parameters and the second alignment calibration parameters.

21. The system of claim 19, wherein the imaging tool further comprises a visible light (VL) camera module configured to receive VL radiation from a target scene and generate VL image data representative of the target scene.

22. The system of claim 21, wherein the processing system is configured to generate a combined IR and VL image, and wherein the image distortion is determined based on the VL image data.

23. The system of claim 9, wherein the processing system is configured to

determine a first amount of image distortion in a first set of image data taken from a first point of view;

determine a second amount of image distortion in a second set of image data taken from a second point of view; and

determine first and second alignment calibration parameters based on the first and second amounts of image distortion, respectively; and

wherein

the alignment tool is configured to assist the user in performing alignment processes in multiple dimensions based on the first and second alignment calibration parameters.

24. The system of claim 23, wherein the first and second fields of view differ by approximately 90 degrees.

25. The system of claim 23, wherein the imaging tool comprises a first camera module and a second camera module, the second camera module being different from the first, and wherein the first set of image data is generated by the first camera module and the second set of image data is generated by the second camera module.

26. The system of claim 23, wherein the imaging tool comprises a first imaging tool and further comprising a second imaging tool, and wherein the first imaging tool is positioned having the first point of view and the second imaging tool is positioned having the second point of view.

27. The system of claim 9, further comprising a test and measurement tool in communication with the processing system and configured to generate vibration data representative of the vibration of the object in at least one dimension.

28. The system of claim 27, wherein vibration data from the test and measurement tool is analyzed and, in the event that the vibration data satisfies a predetermined condition, the processing system is configured to automatically cause the imaging tool to generate image data representative of the object, determine an amount of image distortion in the image data, and determine one or more alignment calibration parameters representative of the amount of misalignment of the object based on the determined amount of image distortion.

29. The system of claim 9, further comprising an external device, and wherein at least one processor of the processing system is located in the external device and wherein the external device comprises a computer, a smartphone, or a tablet.

30. A system comprising one or more non-transitory computer-readable media comprising executable instructions for collectively causing one or more programmable processors to:

receive image data representative of an object;

determine an amount of image distortion present in the received image data;

determine one or more alignment calibration parameters based on the determined amount of image distortion; and

adjust an alignment process according to the one or more alignment calibration parameters.

31. The system of claim 30, further comprising a laser alignment tool, and wherein adjusting an alignment process according to the one or more alignment calibration parameters comprises adjusting one or more alignment settings of the laser alignment tool.

32. The system of claim 30, wherein the alignment tool comprises at least one of the one or more non-transitory computer-readable media and is configured to determine the one or more alignment calibration parameters.

33. The system of claim 30, wherein the one or more non-transitory computer-readable media are further configured to:

receive temperature data representative of a temperature change of the object;

determine an amount of thermal growth of the object based on the received temperature data; and

determine one or more additional alignment calibration parameters; and

wherein

adjusting the alignment process comprises adjusting the alignment process according to the one or more alignment calibration parameters and according to the one or more additional alignment parameters.