Methods, apparatuses, and systems for image-based measurement and inspection of pre-engineered structural components

• US 20080226122A1
• Filed: 01/30/2008
• Published: 09/18/2008
• Est. Priority Date: 01/31/2007
• Status: Active Grant

• Current Assignee: Building Component Verification Systems, Inc.
• Original Assignee: Building Component Verification Systems, Inc.
• Inventors: Thompson, Cyril Robert, Corley, Steven
• Granted Patent: US 8,131,008 B2
• Time in Patent Office: Days
• US Class Current: 382/100
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: G06V 10/10 Image acquisition document image scanning and transmission H04N1/00; control of digital cameras H04N23/60
• CPC Class Codes: G06V 2201/06 Recognition of objects for industrial automation

Abstract

Methods, apparatuses, and systems for image-based measurement and inspection of pre-engineered structural components, such as building trusses and wall panels. A system can include: a light source; a camera; a first memory storage; a second memory storage; and a processing unit configured to (i) detect a characteristic of the structural component, (ii) compare the characteristic to a corresponding characteristic of at least one reference data, and (iii) indicate a result of the comparison. A method can include: causing a light source to illuminate a portion of the structural component, receiving a reflection of the light source from the illuminated portion of the structural component, and storing data corresponding to the intensity of the reflection; comparing the stored data to at least one reference data; and indicating a result of the comparison.

Claims

1. A system for inspecting a pre-engineered structural component, comprising:

a) a light source configured to illuminate a portion of said structural component;

b) a camera configured to (i) receive a reflection of said light source from said structural component and (ii) generate an image output corresponding to said reflection;

c) a memory storage configured to store at least one reference data, said at least one reference data corresponding to at least one reference structural component design; and

d) a processing unit with an internal memory in communication with said light source, said camera, and said memory storage, wherein said processing unit is configured to (i) receive said camera image output into internal memory, (ii) detect a characteristic of said structural component from said camera image output, (iii) compare said characteristic to a corresponding characteristic of said at least one reference data, and (iv) provide a result of said comparison.

2. The system of claim 1, wherein said characteristic is selected from the group consisting of the size of at least one lumber piece, the shape of at least one lumber piece, the color of at least one lumber piece, the absolute position of at least one lumber piece, the relative position of at least one lumber piece, the size of at least one support plate, the shape of at least one support plate, the color of at least one support plate, the absolute position of at least one support plate, the size of at least one identification device, the shape of at least one identification device, the color of at least one identification device, the absolute position of at least one identification device, and combinations thereof.

3. The system of claim 1, wherein said light source is configured to emit radiation having a narrow chromatic bandwidth.

4. The system of claim 1, wherein said light source comprises at least one optical filter.

5. The system of claim 1, wherein said camera is configured to receive radiation having a narrow chromatic bandwidth.

6. The system of claim 1, wherein said camera comprises at least one optical filter.

7. The system of claim 1, wherein said camera includes an environmental housing.

8. The system of claim 1, further comprising a reflective surface.

9. The system of claim 8, wherein said reflective surface is selected from the group consisting of a mirror and a prism.

10. The system of claim 8, further comprising (i) a first optical path from said structural component to said reflective surface and (ii) a second optical path from said reflective surface to said camera.

11. The system of claim 8, further comprising an enclosure for housing said light source, said reflective surface, and said camera.

12. The system of claim 8, further comprising a light source housing containing said light source and said reflective surface, said housing having a proximal opening and a distal opening.

13. The system of claim 12, wherein said light source housing has a uniform interior color.

14. The system of claim 1, further comprising at least one first edge sensor for detecting a leading edge of said structural component, and at least one second edge sensor for detecting a trailing edge of said structural component.

15. The system of claim 1, further comprising an encoder configured to (i) detect the position of said structural component relative to said camera and (ii) generate output corresponding to said position.

16. The system of claim 1, further comprising a motorized roller for moving the structural component from a first position to a second position.

17. The system of claim 1 wherein said processing unit is further configured to compress image output from said camera.

18. The system of claim 17 wherein said image compression configuration is capable of eliminating of backdrop areas of said image output.

19. The system of claim 17 wherein said processing unit is further configured to save compressed images.

20. An apparatus for validating the construction of a pre-engineered structural component, comprising:

a) an emitter for projecting photons towards a portion of said structural component;

b) a receiver for detecting a reflection of said photons from said portion of said structural component and producing an output; and

c) a processor in communication with said emitter, said receiver, and a program wherein said program is adapted to (i) create an electronic image of said structural component from said output, (ii) compare said image to a reference image and (iii) provide a result of said comparison.

21. The apparatus of claim 20, further comprising a means for moving the structural component with respect to said receiver.

22. The apparatus of claim 20, further comprising an encoder for detecting the position of said structural component with respect to said receiver.

23. The apparatus of claim 20, further comprising a sensor for detecting an edge of the structural component.

24. The apparatus of claim 20, wherein said apparatus further comprises at least one reflective surface configured to create (i) a first optical path from said structural component to said at least one reflective surface and (ii) a second optical path from said at least one reflective surface to said receiver.

25. The apparatus of claim 20 wherein said program is further adapted to compress said electronic image.

26. The apparatus of claim 25 wherein said image compression program is capable of elimination of backdrop areas of said electronic image.

27. The apparatus of claim 25 wherein said processor unit is further configured to save compressed images in a memory storage.

28. A method of validating the construction of a pre-engineered structural component, comprising the steps of:

a) moving said structural component from a first position to a second position in front of a backdrop;

b) causing a light source to illuminate said structural component as it moves from said first position to said second position;

c) receiving reflections of said light source from said structural component and backdrop as it moves from said first position to said second position, and storing data in a first portion of a data array, wherein said data corresponds to said reflections;

d) comparing the data in said data array to data in at least one reference array, wherein the data in said at least one reference array corresponds to at least one reference structural component design; and

e) indicating a result of said comparison.

29. The method of claim 28, wherein said step of causing said light source to illuminate said second portion of said structural component further comprises moving said structural component from a first position to a second position.

30. The method of claim 28, further comprising the step of processing said data array to remove backdrop data.

31. The method of claim 28, wherein said step of comparing the data in said data array to the data in said at least one reference array further comprises:

a) selecting one of said at least one reference array;

b) searching the data in said first array to find the presence and relative location of at least one of a lumber piece and a support plate;

c) searching the data in said selected reference array to find the presence and relative location of at least one of a corresponding at least one of a lumber piece and a support plate; and

d) determining how closely the presence and relative location found in said first array corresponds to the presence and location found in said reference array.

32. The method of claim 31 further comprising the step of adjusting the data in said first array for skew.

33. The method of claim 31, wherein said step of selecting one of said at least one reference array comprises (i) detecting the presence of an identification device in said first array and (ii) selecting said at least one reference array corresponding to said identification device.

34. The method of claim 33 wherein the step of detecting said identification device includes searching for one of the group of a bar code, a label, printed text, a machine readable pattern, and combinations thereof.

35. The method of claim 31, wherein said step of selecting one of said at least one reference array comprises (i) receiving an input from a human interface device and (ii) selecting said at least one reference array corresponding to said input.

36. The method of claim 31, wherein said step of selecting one of said at least one reference array comprises (i) determining the presence of a unique support plate and (ii) selecting said at least one reference array corresponding to said unique support plate.

37. The method of claim 36, wherein said step of determining the presence of said support plate comprises:

a) first identifying the presence and relative location of at least one potential support plate;

b) identifying from said at least one potential support plate the presence and relative location of at least one likely support plate; and

c) identifying from said at least one likely support plate the presence and relative location of said support plate.

38. The method of claim 28, wherein said indicating step comprises displaying a representation of said first array and a representation of said reference array on a monitor.

39. The method of claim 28, wherein said indicating step comprises one of the group of:

providing an audio signal, providing a visual signal, providing a printed report, providing a video report, and combinations thereof.

40. A method of validating the construction of a pre-engineered structural component, comprising:

a) creating at least one computer readable image of said structural component;

b) calibrating the dimensions and orientation of said at least one image;

c) selecting a reference image, said reference image corresponding to a reference structural component design;

d) comparing said computer readable image with said selected reference image; and

e) indicating a result of said comparison.

41. The method of claim 40, further comprising the step of moving said structural component from a first position to a second position by at least one mechanized roller.

42. The method of claim 40, wherein said step of creating said at least one computer readable image comprises:

a) First, detecting a leading edge of said structural component;

b) upon such first deletion, beginning reading data from at least one camera;

c) then detecting a trailing edge of said structural component; and

d) upon such second detection, stopping reading data from said at least one camera.

43. The method of claim 42, wherein said step of detecting said leading edge comprises determining when an output of a first edge sensor changes state.

44. The method of claim 42, wherein said step of detecting said trailing edge comprises determining when an output of a second edge sensor changes state.

45. The method of claim 42, further comprising:

a) processing said at least one computer readable image to remove data that does not correspond to at least one of the group consisting of a lumber piece, a support plate, and an identification device;

b) mathematically compressing said at least one computer readable image; and

c) storing said at least one computer readable image in a memory device.

46. The method of claim 40, further comprising creating at least two computer readable images of said structural component.

47. The method of claim 46, further comprising the step of correlating said at least two computer readable images.

48. The method of claim 47 wherein said correlating step comprises the sub-steps of:

a) locating a first feature in a first of said at least two computer readable images;

b) locating a second feature in a second of said at least two computer readable images, wherein said second feature corresponds to said first feature; and

c) using a normalized cross correlation algorithm to correlate said first computer readable image and said second computer readable image about said first and said second features, respectively.

49. The method of claim 40, wherein said step of calibrating said dimensions and said orientation of said at least one computer readable image comprises the sub-steps of:

a) selecting a portion of at least one support plate candidate;

b) computing the power cepstrum of said selected portion of said at least one support plate candidate;

c) identifying from said power cepstrum said at least one support plate; and

d) adjusting said dimensions and said orientation of said at least one computer readable image corresponding to stored dimensions of said at least one support plate.

50. The method of claim 40, wherein said step of selecting one of said at least one reference image comprises (i) determining the presence of an identification device and (ii) selecting a reference image corresponding to said identification device.

51. The method of claim 50, wherein said step of determining the presence of said identification device comprises searching for a known identification device pattern.

52. The method of claim 50, wherein said step of determining the presence of said identification device comprises:

a) selecting a portion of at least one identification device candidate;

b) computing the power cepstrum of said selected portion of said at least one identification device candidate; and

c) identifying from said power cepstrum said identification device.

53. The method of claim 40, wherein said step of selecting one of said at least one reference image comprises (i) receiving an input from a human interface device and (ii) selecting said reference image corresponding to said input.

54. The method of claim 40, wherein said step of selecting one of said at least one reference image comprises (i) identifying a support plate from at least one of a bar code, a label, printed text, and a machine readable pattern, and (ii) selecting said one of said at least one reference image corresponding to said identification.

55. The method of claim 54, wherein said step of determining the presence of said support plate comprises:

a) selecting a portion of at least one support plate candidate;

b) computing the power cepstrum of said selected portion of said at least one support plate candidate; and

c) identifying from said power cepstrum said support plate.

56. An automated system for taking images of a pre-engineered structural component, comprising:

a) a lighting enclosure comprising a proximal opening and a distal opening;

b) at least one camera provided near said distal opening;

c) at least one structural component detector;

d) a processor in communication with said at least one structural component detector and said at least one camera; and

e) a program associated with said processor, wherein said program and said processor are configured to capture and process at least one image of said structural component received from said at least one camera.

57. The system of claim 56 wherein said program is further configured to compress said at least one image.

58. The system of claim 57 wherein said program is further configured to store said compressed image.

59. The system of claim 56 further comprising at least one position sensor.

60. The system of claim 56, wherein said processor and said program are configured to associate an output of said position sensor and the timing of said camera.

61. The system of claim 56, wherein said at least one camera is configured with a resolution sufficient to measure critical dimensions of said structural component within tolerances determined by a design specification of said structural component.

62. The system of claim 56, wherein said at least one camera comprises an optical filter for increasing the visual contrast between parts of said structural component and a backdrop.

63. The system of claim 56, further comprising an enclosure configured to protect said at least one camera from dust, moisture, and temperature extremes.

64. The system of claim 56, wherein said lighting enclosure is configured to block most ambient light and configured to add light suitable for reception by said at least one camera.

65. The system of claim 64, wherein said lighting enclosure further comprises a reflective surface.

66. The system of claim 65, wherein the distance between said reflective surface and said structural component is less than a distance between said reflective surface and said at least one camera.

67. The system of claim 56, wherein the interior of said lighting enclosure is of a uniform color.

68. The system of claim 56, wherein a backdrop is provided adjacent to said proximal opening, said backdrop having a uniform appearance suitable for creating a contrast with said structural component.

69. The system of claim 56, further comprising at least one motorized roller for advancing said structural component in a direction.

70. The system of claim 56, wherein said processor and said program are configured to identify at least one part of said structural component from said at least one image.

71. The system of claim 61, wherein said processor and said program are configured to (i) identify at least one part of said structural component from said at least one image, and (ii) measure at least one critical dimension of said structural component from said at least one image.

72. The system of claim 71, wherein said processor and said program are configured to compare said at least one critical dimension of said structural component with a corresponding critical dimension in a reference structural component design.

73. The system of claim 72, wherein said processor and said program are configured to identify said reference structural component design by automatically detecting at least one identifier from said at least one image of said structural component.

74. The system of claim 73 wherein said at least one identifier is selected from the group of a label, a barcode, text, and combinations thereof.

75. The system of claim 72, wherein said processor and said program are configured to identify said reference structural component design by receiving a manually provided identifier.

76. The system of claim 56, further comprising a means for graphically displaying a result of said processing overlaid on said at least one image of said structural component.

77. The method of claim 56, further comprising one of the group of:

an audio signal device, a visual signal device, a printer, a video display, and combinations thereof.

78. A method for inspecting a pre-engineered structural component, comprising:

a) capturing at least one image from at least one side of said structural component;

b) identifying said structural component;

c) measuring at least one dimension of said structural component contained in said at least one image;

d) comparing said at least one dimension to a corresponding dimension in a reference structural component design; and

e) reporting a result of the comparison.

79. The method of claim 78, wherein said step of reporting comprises graphically displaying a result of said comparison superimposed over said images.

80. The system of claim 78 comprising the further step of compressing said at least one image.

81. The system of claim 80 comprising the further step of storing said compressed image.

82. The method of claim 78, further comprising the step of moving said structural component from a first position to a second position by at least one mechanized roller.

83. The method of claim 78, wherein said step of capturing said at least one image comprises:

a) first, detecting a leading edge of said structural component;

b) upon such first detection, beginning capturing images of said structural component;

c) then detecting a trailing edge of said structural component; and

d) upon such second detection, stopping capturing images.

84. The method of claim 78, further comprising capturing at least two computer readable images of said structural component.

85. The method of claim 84, further comprising the step of correlating said at least two computer readable images,

86. The method of claim 85 wherein said correlating step comprises the sub-steps of:

a) locating a first feature in a first of said at least two computer readable images;

b) locating a second feature in a second of said at least two computer readable images, wherein said second feature corresponds to said first feature; and

c) using a normalized cross correlation algorithm to correlate said first computer readable image and said second computer readable image about said first and said second features, respectively.

87. The method of claim 78 comprising the further steps of selecting a reference structural component design by (i) determining the presence of an identification device in said at least one image, and (ii) selecting a reference structural component design corresponding to said identification device.

88. The method of claim 87, wherein said step of determining the presence of said identification device comprises searching for a known identification device pattern.

89. The method of claim 87, wherein said step of selecting one of said at least one reference image comprises (i) receiving an input from a human interface device and (ii) selecting said reference image corresponding to said input.

90. A system for inspecting a pre-engineered structural component, comprising:

a) a means for illuminating a portion of said structural component;

b) a means for receiving a reflection from said structural component and generating an image output corresponding to said reflection;

c) a means for storing at least one reference data, said at least one reference data corresponding to at least one reference structural component design; and

d) a processing means with a memory means in communication with said illumination means, said receiving means and said storing means, said processing means being is configured to (i) receive said image output into said memory means, (ii) detect a characteristic of said structural component from said image output, (iii) compare said characteristic to a corresponding characteristic of said at least one reference data, and (iv) provide a result of said comparison.

91. An automated system for taking images of a pre-engineered structural component, comprising:

a) an enclosure means comprising a proximal opening and a distal opening;

b) a camera means provided near said distal opening;

c) a means for detecting at least one structural component;

d) a processing means in communication with said detecting means and said camera means; and

e) a program means associated with said processing means, wherein said program means and said processing means are configured to capture and process at least one image of said structural component received from said camera means.