Two-dimensional mapping system and method of operation

• US 10,282,854 B2
• Filed: 10/10/2017
• Issued: 05/07/2019
• Est. Priority Date: 10/12/2016
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Zweigle, Oliver, Frank, Aleksej, Becker, Bernd-Dietmar
• Primary Examiner(s): Zalalee, Sultana M
• Application Number:
  US15/729,010
• Publication Number:
  US 20180101961A1
• Time in Patent Office: 574 Days
• Field of Search: None
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: G01S 17/89 for mapping or imaging
• CPC Class Codes: G01S 7/4808 Evaluating distance, position or velocity data
• CPC Class Codes: G06T 11/60 Editing figures and text; Combining figures or text
• CPC Class Codes: G06T 2200/04 involving 3D image data
• CPC Class Codes: G06T 2207/10028 Range image; Depth image; 3D point clouds
• CPC Class Codes: G06T 2207/20108 Interactive selection of 2D slice in a 3D data set
• CPC Class Codes: G06T 2207/20221 Image fusion; Image merging
• CPC Class Codes: G06T 2210/04 Architectural design, interior design
• CPC Class Codes: G06T 7/337 involving reference images or patches
• CPC Class Codes: G06T 7/521 from laser ranging, e.g. using interferometry; from the projection of structured light

Abstract

A method and system of generating a two-dimensional map with an optical scanner is provided. The method comprises acquiring coordinate data of points in an area being scanned with a mobile optical scanner. A current 2D map from the coordinate data is generated. A copy of the current 2D map is saved on a periodic or aperiodic basis. At least one data registration error is identified in the current 2D map. The saved copy of the current 2D map from a point in time prior to the registration error is determined. A second data set of coordinate data acquired after the determined saved copy is identified. The second data set is aligned to the determined saved copy to form a new current 2D map. The new current 2D map is stored in memory.

Claims

1. A method of generating a two-dimensional (2D) map, the method comprising:

acquiring coordinate data of points in an area being scanned with a mobile optical scanner;

generating a current 2D map from the coordinate data;

saving a copy of the current 2D map on a periodic or aperiodic basis;

identifying at least one data registration error in the current 2D map;

determining the saved copy of the current 2D map from a point in time prior to the registration error;

identifying a second data set of coordinate data acquired after the determined saved copy;

aligning the second data set to the determined saved copy to form a new current 2D map; and

storing the new current 2D map.

2. The method of claim 1 wherein the aligning of the second data set comprises deleting the second data set and re-scanning a portion of the area associated with the second data set.

3. The method of claim 1 wherein the aligning of the second data set comprises performing by the operator at least one of a shift or a rotation of the second data set relative to the determined saved copy.

4. The method of claim 1 wherein the aligning of the second data set comprising:

performing by the operator at least one of a shift or a rotation of the second data set relative to the determined saved copy;

identifying overlapping natural features in the determined saved copy and the second data set; and

automatically shifting and rotating the second data set with the determined saved copy when the overlapping natural features are aligned by the operator within a predetermined threshold.

5. The method of claim 1 wherein the aligning of the second data set comprises

comparing the determined saved copy against second data set until an overlay is reached within a predetermined probability threshold;

determining the offset vector from a previous map origin to a new map origin in a coordinate system of a previous map; and

applying the offset vector to all positions in a new map.

6. A method of generating a two-dimensional map with a scanner, the method comprising:

acquiring a first set coordinate data with an optical scanner;

determining a predetermined amount of time has elapsed or a predetermined distance has been scanned;

storing in memory of a processor operably coupled to the optical scanner a first copy of a two-dimensional map generated from the first set of coordinate data acquired during the predetermined amount of time or the predetermined distance;

acquiring a second set of coordinate data with the optical scanner;

generating a current two-dimensional map based at least in part on the first set of coordinate data and the second set of coordinate data;

determining a registration error in the current two-dimensional map;

determining the first copy does not include the registration error;

registering the second set of coordinate data with the first copy; and

replacing the current two-dimensional map with a new two-dimensional map based at least in part on the registration of the second set of coordinate data to the first copy.

7. The method of claim 6, wherein the step of registering the second set of coordinate data further includes manually aligning, by the operator, the second set of coordinate data to the first copy.

8. The method of claim 6, wherein the step of registering the second set of coordinate data further comprises:

manually aligning, by the operator, the second set of coordinate data to the first copy; and

automatically moving and aligning the second set of coordinate data when the operator has moved the second set of coordinate data within a predetermined distance of the first copy.

9. The method of claim 6, wherein the step of registering the second set of coordinate data further comprises:

matching a geometrical structure of the first copy with the second set of coordinate data; and

aligning the first copy and the second set of coordinate data when an overlay of the geometrical structure is within a predetermined probability threshold.

10. The method of claim 6, wherein the step of registering the second set of coordinate data comprises:

deleting the second set of coordinate data;

moving the optical scanner to a location in real-space adjacent an end of a geometrical structure of the first copy;

reacquiring a third set of coordinate data with the optical scanner, wherein the third set of coordinate data corresponds to an area covered by the second set of coordinate data.

11. The method of claim 6, further comprising bifurcating the current two-dimensional map to separate coordinate data acquired after the first copy was stored.

12. The method of claim 6, further comprising:

storing in memory of a processor operably coupled to the optical scanner a second copy of a two-dimensional map generated from a third set of coordinate data acquired during a second predetermined amount of time or a second predetermined distance;

storing in memory of a processor operably coupled to the optical scanner a third copy of a two-dimensional map generated from a fourth set of coordinate data acquired during a fourth predetermined amount of time or a fourth predetermined distance; and

in response to determining a registration error determining the which of the first copy, the second copy or the third copy that is latest in time that does not include the registration error.

13. A system of generating a two-dimensional map with a scanner, the system comprising:

an optical scanner;

one or more processors that are operably coupled to memory, the one or more processors being responsive to executable computer instructions, the executable computer instructions comprising

acquiring a first set coordinate data with the optical scanner;

determining a predetermined amount of time has elapsed or a predetermined distance has been scanned;

storing in the memory a first copy of a two-dimensional map generated from the first set of coordinate data acquired during the predetermined amount of time or the predetermined distance;

acquiring a second set of coordinate data with the optical scanner;

generating a current two-dimensional map based at least in part on the first set of coordinate data and the second set of coordinate data;

determining a registration error in the current two-dimensional map;

determining the first copy does not include the registration error;

registering the second set of coordinate data with the first copy; and

replacing the current two-dimensional map with a new two-dimensional map based at least in part on the registration of the second set of coordinate data to the first copy.

14. The system of claim 13, wherein the step of registering the second set of coordinate data further includes manually aligning, by the operator, the second set of coordinate data to the first copy.

15. The system of claim 13, wherein the step of registering the second set of coordinate data further comprises:

manually aligning, by the operator, the second set of coordinate data to the first copy; and

automatically moving and aligning the second set of coordinate data when the operator has moved the second set of coordinate data within a predetermined distance of the first copy.

16. The system of claim 13, wherein the step of registering the second set of coordinate data further comprises:

matching a geometrical structure of the first copy with the second set of coordinate data; and

aligning the first copy and the second set of coordinate data when an overlay of the geometrical structure is within a predetermined probability threshold.

17. The system of claim 13, wherein the step of registering the second set of coordinate data comprises:

deleting the second set of coordinate data;

moving the optical scanner to a location in real-space adjacent an end of a geometrical structure of the first copy;

reacquiring a third set of coordinate data with the optical scanner, wherein the third set of coordinate data corresponds to an area covered by the second set of coordinate data.

18. The system of claim 13, further comprising bifurcating the current two-dimensional map to separate coordinate data acquired after the first copy was stored.

19. The system of claim 13, further comprising:

storing in memory of a processor operably coupled to the optical scanner a second copy of a two-dimensional map generated from a third set of coordinate data acquired during a second predetermined amount of time or a second predetermined distance;

storing in memory of a processor operably coupled to the optical scanner a third copy of a two-dimensional map generated from a fourth set of coordinate data acquired during a fourth predetermined amount of time or a fourth predetermined distance; and

in response to determining a registration error determining the which of the first copy, the second copy or the third copy that is latest in time that does not include the registration error.