WIRELESS VISION SYSTEMS AND METHODS FOR USE IN HARSH ENVIRONMENTS

• US 20150073584A1
• Filed: 09/10/2014
• Published: 03/12/2015
• Est. Priority Date: 09/10/2013
• Status: Abandoned Application

• Current Assignee: Cognex Corporation
• Original Assignee: Cognex Corporation
• Inventors: Costigan, George, Wang, Lei, Goodale, Andrew, Schilling, Schilling, King, David R
• Application Number:
  US14/482,518
• Publication Number:
  US 20150073584A1
• Time in Patent Office: Days
• US Class Current: 700/186
• CPC Class Codes: B23Q 17/2428 for measuring existing positions of tools or workpieces
• CPC Class Codes: G05B 19/401 characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes G05B19/19 takes precedence
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 2219/37009 Calibration of vision system, camera, adapt light level
• CPC Class Codes: G05B 2219/45145 Milling

Abstract

A chuck or spindle mountable wireless vision system and method for use in harsh environments. The vision system includes a sealed housing. The sealed housing includes a tool holder interface to couple to the chuck or spindle of a machine. An optical system to acquire an image is positioned within the sealed housing, the optical system including a processor, memory, and machine vision software to perform at least a portion of image processing. A wireless communication module is operatively coupled to the optical system to wirelessly communicate image data. And, a power source, the power source operatively coupled to the optical system and the wireless communication module.

Claims

1. A chuck or spindle mountable vision system, the system comprising:

a sealed housing, the sealed housing including a tool holder interface and a base, the tool holder interface coupled to a first end of the base, and a window on the second end of the base;

an optical system to acquire an image through the window, the optical system including a processor, memory, and machine vision software;

a wireless communication module operatively coupled to the optical system to wirelessly communicate data, including image data generated by the machine vision software; and

a power source, the power source operatively coupled to the optical system and the wireless communication module.

2. The system according to claim 1,

wherein the optical system is a non-contact optical system.

3. The system according to claim 1,

wherein the vision system is mounted to the chuck or spindle of a CNC machine.

4. The system according to claim 1,

wherein the tool holder interface is mounted to the chuck or spindle of a CNC machine.

5. The system according to claim 3,

wherein the vision system acquires the image and generates image data during a process controlled by the CNC machine.

6. The system according to claim 5,

wherein the wireless communication module wirelessly communicates the image data during the process controlled by the CNC machine.

7. The system according to claim 1,

wherein the power source is a rechargeable power source.

8. The system according to claim 1,

further including a communication adapter, the communication adapter to transmit and receive the wireless communications to and from the wireless communication module.

9. The system according to claim 1,

wherein the communication adapter is positioned in a box, the box having at least an IP67 or equivalent rating.

10. The system according to claim 1,

wherein the tool holder interface includes a pull stud.

11. The system according to claim 1,

wherein the sealed housing has at least an IP67 or equivalent rating.

12. A chuck or spindle mountable vision system, the system comprising:

a sealed housing, the sealed housing including a tool holder interface to couple to the chuck or spindle;

an optical system to acquire an image, the optical system positioned within the sealed housing, the optical system including a processor, memory, and machine vision software to perform at least a portion of image processing;

a wireless communication module operatively coupled to the optical system to wirelessly communicate image data; and

a power source, the power source operatively coupled to the optical system and the wireless communication module.

13. The system according to claim 12,

wherein the sealed housing has at least an IP67 or equivalent rating.

14. The system according to claim 12,

wherein the sealed housing further includes a base having a first end and a second end, the tool holder interface sealingly coupled to the first end of the base, the base including a window on the second end of the base.

15. A method for auto-calibrating a vision system, the vision system coupled to a chuck or spindle of a CNC machine, the CNC machine having a work space, the method comprising the steps of:

a. acquiring at least one image of at least a portion of the work space;

b. locating a feature in the image;

c. rotating the spindle of the CNC machine;

d. acquiring at least one new image of at least a portion of the work space;

e. locating the feature in the at least one new image;

f. calculating a center of rotation;

g. moving the work space;

h. acquiring at least one subsequent image of at least a portion of the work space;

i. locating the feature in the at least one subsequent image; and

j. creating a hand-eye calibration between the vision system and the CNC machine.

16. The method according to claim 15,

further including repeating steps a through e at least once before performing step f.

17. The method according to claim 15,

wherein the feature is one of a calibration plate, a fiducial on the work space, and a texture on the work space.

18. The method according to claim 15,

further including repeating steps h and i at least once before performing step j.

19. The method according to claim 18,

wherein repeating steps h and i acquires data for at least one additional work space axis.

20. The method according to claim 15,

wherein the vision system comprises an optical system, a wireless communication module, and a power source operatively coupled to the optical system and wireless communication module, the optical system, wireless communication module, and power source positioned within a sealed housing.

21. The method according to claim 20,

wherein the method is controlled by the CNC machine.

22. The method according to claim 15,

further including using the vision system to acquire a run-time image during a machining process controlled by the CNC machine.