Method and System for Two-Dimensional and Three-Dimensional Inspection of a Workpiece

• US 20070280501A1
• Filed: 05/31/2006
• Published: 12/06/2007
• Est. Priority Date: 05/31/2006
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Walton, Steven R
• Granted Patent: US 9,052,294 B2
• Time in Patent Office: Days
• US Class Current: 382/100
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 2201/0626 Use of several LED's for spatial resolution
• CPC Class Codes: G01N 2201/0627 Use of several LED's for spectral resolution
• CPC Class Codes: G06T 2207/10152 Varying illumination
• CPC Class Codes: G06T 2207/30164 Workpiece; Machine component
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

A system and method for inspecting a workpiece are provided. According to one embodiment, the system includes a plurality of illumination sources positioned proximate to the workpiece and each operable to generate at least one respective illumination beam to illuminate at least a portion of the workpiece, wherein each beam has a different respective color. The system also includes at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece including the illumination beams incident thereon. In addition, the system includes a data system capable of providing simultaneous two-dimensional and three-dimensional information indicative of the workpiece based on the image acquired by the camera.

Claims

1. An inspection system for inspecting a workpiece comprising:

a plurality of illumination sources positioned proximate to the workpiece and each operable to illuminate at least a portion of the workpiece with at least one respective illumination beam, each illumination beam having a different respective color;

at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece in response to illumination of at least a portion of the workpiece by the illumination beams; and

a data system capable of providing two-dimensional and three-dimensional information indicative of the workpiece based on the image acquired by the camera.

2. The system according to claim 1, wherein the plurality of illumination sources produce respective illumination beams that are configured to illuminate a respective feature of the workpiece.

3. The system according to claim 2, wherein the plurality of illumination sources produce a number of illumination beams that are configured to illuminate respective edges of a gap in the workpiece.

4. The system according to claim 1, wherein the plurality of illumination sources comprises at least one laser fan beam generator and at least one LED array.

5. The system according to claim 4, wherein a respective illumination beam comprises a fan beam or a structured LED light wash.

6. The system according to claim 1, wherein the data system is capable of providing at least one of information indicative of respective edges of a workpiece, a gap in the workpiece, a topology of the workpiece, a shape of the workpiece, and a flaw in the workpiece.

7. The system according to claim 1, wherein each of the plurality of illumination sources is positioned to provide a respective illumination beam that illuminates the workpiece at an oblique incidence angle.

8. The system according to claim 1, wherein the data system is capable of combining information attributable to the illumination beams that are generated by each of the plurality of illumination sources and that are independent from one another.

9. The system according to claim 1, wherein the data system is capable of providing information indicative of the workpiece during processing of the workpiece.

10. A method for inspecting a workpiece comprising:

illuminating at least a portion of the workpiece with a plurality of colored illumination beams;

capturing at least one image of at least a portion of the workpiece illuminated by the illumination beams; and

providing two-dimensional and three-dimensional information indicative of the workpiece based on the captured image.

11. The method according to claim 10, further comprising performing a manufacturing process on a moving workpiece during the illuminating and capturing steps.

12. The method according to claim 11, wherein illuminating comprises illuminating at least a portion of the workpiece with at least one colored illumination beam in a direction substantially perpendicular to the moving workpiece.

13. The method according to claim 10, wherein providing comprises combining information that is attributable to each of the plurality of colored illumination beams and that are independent from one another.

14. The method according to claim 10, wherein providing comprises providing at least one of information indicative of respective edges of a workpiece, a gap in the workpiece, a topology of the workpiece, a shape of the workpiece, and a flaw in the workpiece.

15. The method according to claim 10, wherein the illuminating step comprises illuminating the plurality of colored illumination beams with respective illumination sources.

16. The method according to claim 15, further comprising at least one of determining the color of a respective colored illumination beams, a shape of a respective colored illumination beam, a location of a respective illumination source, and a pointing direction of a respective illumination source.

17. The method according to claim 10, wherein illuminating comprises illuminating the workpiece with a respective colored illumination beam at an oblique incidence angle.

18. The method according to claim 10, wherein illuminating comprises illuminating the workpiece with at least one fan beam and at least one structured LED light wash.

19. An inspection system for inspecting a composite workpiece laminated with a plurality of composite tape or tow plies comprising:

a plurality of illumination sources positioned proximate to the workpiece and each operable to illuminate at least a portion of the workpiece with at least one respective illumination beam;

at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece in response to the illumination of at least a portion of the workpiece by the illumination beam; and

a data system capable of providing information indicative of the workpiece based on the image acquired by the camera.

20. The system according to claim 19, wherein each illumination beam has a different respective color.

21. The system according to claim 19, wherein the data system is capable of providing at least one of information indicative of respective edges of a tape ply, a gap between tape plies, a topology of a tape ply, a wrinkle in a tape ply, and a flaw in a tape ply.

22. The system according to claim 19, wherein the data system is capable of providing simultaneous two-dimensional and three-dimensional information indicative of the workpiece.

23. The system according to claim 19, wherein each of the plurality of illumination sources is positioned to provide a respective illumination beam that illuminates the workpiece at an oblique incidence angle.

24. The system according to claim 19, wherein the plurality of illumination sources comprises at least one laser fan beam generator and at least one LED array.

25. The system according to claim 24, wherein a respective illumination beam comprises a fan beam or a structured LED light wash.