SYSTEM AND METHOD OF AUTOMATED 3D SCANNING FOR VEHICLE MAINTENANCE

• US 20150269792A1
• Filed: 03/18/2014
• Published: 09/24/2015
• Est. Priority Date: 03/18/2014
• Status: Active Grant

• Current Assignee: Robert Bruce Wood
• Original Assignee: Robert Bruce Wood
• Inventors: Wood, Robert Bruce
• Granted Patent: US 9,153,079 B1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G01M 17/007 Wheeled or endless-tracked vehicles G01M17/08 takes precedence
• CPC Class Codes: G06Q 30/0283 Price estimation or determination
• CPC Class Codes: G06Q 40/08 Insurance
• CPC Class Codes: G07C 5/006 Indicating maintenance
• CPC Class Codes: G07C 5/0808 Diagnosing performance data testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005
• CPC Class Codes: Y10S 901/44 inspection

Abstract

System and method for using automated 3D scans to diagnose the mechanical status of substantially intact vehicles. One or more processor controlled 3D scanners utilize optical and other methods to assess the exposed surfaces of various vehicle components. Computer vision and other computerized pattern recognition techniques then compare the 3D scanner output versus a reference computer database of these various vehicle components in various normal and malfunctioning states. Those components judged to be aberrant are flagged. These flagged components can be reported to the vehicle users, as well as various insurance or repair entities. In some embodiments, the 3D scans can be performed using time-of-flight cameras, and optionally infrared, stereoscopic, and even audio sensors attached to the processor controlled arm of a mobile robot. Much of the subsequent data analysis and management can be done using remote Internet servers.

Claims

1. A method of determining a mechanical status of a vehicle, said vehicle comprising a plurality of mechanical components at different positions on said vehicle, at least some of said mechanical components having visible component surfaces, method comprising:

using at least one mobile 3D scanner to scan these visible component surfaces and positions, thereby producing 3D scanner output data of at least some of these visible component surfaces and positions;

said at least one mobile 3D scanner configured to be automatically positioned, under processor control, near a plurality of said mechanical components during said scan so that the positions and orientations of said at least one mobile 3D scanner can be automatically determined during said scan;

using at least one computer processor to analyze said 3D scanner output data versus a computer database of comparative 3D scan data, said comparative 3D scan data comprising at least one of 3D scans of similar or identical vehicles in both ideal and previously identified aberrant states, or 3D models of the similar or identical vehicles in both ideal and previously identified aberrant states;

further inputting the identity of said vehicle into said computer database, and linking said identity with said 3D scanner output data;

using said at least one computer processor and image recognition software to determine differences between said 3D scanner output data, and said comparative 3D scan data, thereby determining and flagging those said plurality mechanical components that match one or more previously identified aberrant states;

and storing or outputting vehicle identified data pertaining to at least those flagged mechanical components.

2. The method of claim 1, wherein said at least one mobile 3D scanner configured to be automatically positioned under processor control is attached to a processor controlled mobile robot;

and

the position and orientation of said processor controlled mobile robot, relative to said vehicle are controlled by said processor;

and said positions and orientations of said at least one mobile 3D scanner are automatically determined by said processor controlled mobile robot.

3. The method of claim 2, wherein said processor controlled mobile robot is further configured with a plurality of 3D scanners, at least some of said plurality of 3D scanners affixed to flexible robotic appendages, and said processor controlled mobile robot is further configured to execute a pre-planned route that passes over multiple mechanical components of said vehicle.

4. The method of claim 1, wherein at least one mobile 3D scanner is a time-of-flight camera, laser scanning camera, or stereo vision 3D scanner.

5. The method of claim 4, wherein said at least one mobile 3D scanner further comprises at least one of an infrared sensor, vibration sensor, video camera, or at least one microphone.

6. The method of claim 1, wherein at least some of said vehicle'"'"'s plurality of mechanical components are operating during said scan, thereby causing vibrations, or motions, or heat changes in at least some of operating components during said scan;

wherein said at least one mobile 3D scanner is further configured to detect said vibrations or motions or sound or heat changes in at least some of said vehicle'"'"'s operating components during said scan, and transmit operating component vibration or motion or sound or heat data to said computer database of comparative 3D scan data along with said 3D scanner output data;

wherein said computer database of comparative 3D scan data further comprises vibration or motion or sound or heat data of operating components in said similar or identical vehicles in both ideal and previously identified aberrant states;

further using said at least one computer processor to determine differences between said vibration or motion or sound or heat data and computer database comparative 3D scan data, and further determine if said vibration or motions or sound or heat data further identifies if any of said mechanical components further match previously identified aberrant states.

7. The method of claim 1, wherein at least some of said plurality of mechanical components comprise engine components, and said previously identified aberrant states provides information pertaining to a need for maintenance of at least some of said engine components.

8. The method of claim 1, wherein said computer database of comparative 3D scan data resides on at least one server that is located remotely from said at least one mobile 3D scanner, but which is able to exchange data with said at least one mobile 3D scanner over a computer network.

9. The method of claim 1, further storing said vehicle identified data pertaining to said flagged mechanical components on at least one Internet server;

further using at least one computerized device to transmit a vehicle identity and status inquiry to said Internet server;

wherein in response to said vehicle identity and status inquiry, further using said Internet server to associate said vehicle identity with said flagged mechanical components, and transmitting vehicle identity specific information pertaining to those flagged mechanical components to said computerized device.

10. The method of claim 9, further using said at least one Internet server to automatically transmit information pertaining to said vehicle identity and at least some of said flagged mechanical components to at least one computerized device associated with a vehicle repair or insurance facility;

using said at least one repair or insurance facility computerized device to transmit estimated repair costs or insurance authorization for at least some of said flagged mechanical components associated with said vehicle identity to said at least one Internet server;

storing said estimated repair costs or insurance authorization in said at least one Internet server database; and

in response to said vehicle identity and status inquiry, further using said Internet server to associate said vehicle identity with said flagged mechanical components and said estimated repair costs or insurance authorization, and further transmitting vehicle identity specific information pertaining to those flagged mechanical components and estimated repair costs or insurance authorization to said computerized device.

11. A method of determining a mechanical status of a vehicle, said vehicle comprising a plurality of mechanical components at different positions on said vehicle, at least some of said mechanical components having visible component surfaces, method comprising:

using at least one mobile 3D scanner to scan these visible component surfaces and positions, thereby producing 3D scanner output data of at least some of these visible component surfaces and positions;

said at least one mobile 3D scanner configured to be automatically positioned, under processor control, near a plurality of said mechanical components during said scan so that the positions and orientations of said at least one mobile 3D scanner can be automatically determined during said scan;

using at least one computer processor to analyze said 3D scanner output data versus a computer database of comparative 3D scan data, said comparative 3D scan data comprising at least one of 3D scans of similar or identical vehicles in both ideal and previously identified aberrant states, or 3D models of the similar or identical vehicles in both ideal and previously identified aberrant states;

further inputting the identity of said vehicle into said computer database, and linking said identity with said 3D scanner output data;

using said at least one computer processor and image recognition software to determine differences between said 3D scanner output data, and said comparative 3D scan data, thereby determining and flagging those said plurality mechanical components that match one or more previously identified aberrant states;

and storing vehicle identified data pertaining to at least those flagged mechanical components on at least one Internet server;

further using said at least one Internet server to automatically transmit information pertaining to said vehicle identity and at least some of said flagged mechanical components to at least one computerized device associated with a vehicle repair or insurance facility;

using said at least one repair or insurance facility computerized device to transmit estimated repair costs or insurance authorization for at least some of said flagged mechanical components associated with said vehicle identity to said at least one Internet server and storing said estimated repair costs or insurance authorization in said at least one Internet server database;

further using at least one computerized device to transmit a vehicle identity and status inquiry to said Internet server;

wherein in response to said vehicle identity and status inquiry, further using said Internet server to associate said vehicle identity with said flagged mechanical components, and transmitting vehicle identity specific information pertaining to those flagged mechanical components and estimated repair costs or insurance authorization to said computerized device.

12. The method of claim 11, wherein said at least one mobile 3D scanner configured to be automatically positioned under processor control is attached to a processor controlled mobile robot;

the position and orientation of said processor controlled mobile robot, relative to said vehicle are controlled by said processor;

said positions and orientations of said at least one mobile 3D scanner are automatically determined by said processor controlled mobile robot; and

wherein said at one mobile 3D scanner is affixed to at least one flexible robotic appendage, and said processor controlled mobile robot is further configured to execute a pre-planned route that passes over multiple mechanical components of said vehicle.

13. The method of claim 11, wherein at least one mobile 3D scanner is a time-of-flight camera, laser scanning camera, or stereo vision 3D scanner;

and

wherein said at least one mobile 3D scanner further comprises at least one of an infrared sensor, vibration sensor, video camera, or at least one microphone.

14. The method of claim 11, wherein at least some of said vehicle'"'"'s plurality of mechanical components are operating during said scan, thereby causing vibrations or motions or sound or heat changes in at least some of operating components during said scan;

wherein said at least one mobile 3D scanner is further configured to detect said vibrations or motions or sound or heat changes in at least some of said vehicle'"'"'s operating components during said scan, and transmit operating component vibration or motion or sound or heat data to said computer database of comparative 3D scan data along with said 3D scanner output data;

wherein said computer database of comparative 3D scan data further comprises vibration or motion or sound or heat data of operating components in said similar or identical vehicles in both ideal and previously identified aberrant states;

further using said at least one computer processor to determine differences between said vibration or motion or sound or heat data and computer database comparative 3D scan data, and further determine if said vibration or motion or sound or heat data further identifies if any of said mechanical components further match previously identified aberrant states; and

wherein at least some of said plurality of mechanical components comprise engine components, and said previously identified aberrant states provides information pertaining to a need for maintenance of at least some of said engine components.

15. A method of using at least one Internet connected server comprising a computer database, at least one computer processor, and an Internet network connection to determine a mechanical status of a vehicle, said vehicle comprising a plurality of mechanical components at different positions on said vehicle, at least some of said mechanical components having visible component surfaces, said method comprising:

receiving, on said at least one Internet connected server, 3D scanner output data produced by at least one mobile 3D scanner that resulted from scanning at least some of said visible component surfaces and positions;

further receiving, on said at least one Internet connected server, information pertaining to a vehicle identity of said vehicle;

using said at least one computer processor to analyze said 3D scanner output data versus a computer database of comparative 3D scan data, said comparative 3D scan data comprising at least one of 3D scans of similar or identical vehicles in both ideal and previously identified aberrant states, or 3D models of the of similar or identical vehicles in both ideal and previously identified aberrant states;

using said at least one computer processor and image recognition software to determine differences between said 3D scanner output data, and said comparative 3D scan data, thereby determining and flagging those said mechanical components that match one or more previously identified aberrant states;

and using said at least one Internet connected server to store or transmit vehicle identified data pertaining to at least those mechanical components that match said one or more previously identified aberrant states.

16. The method of claim 15, further storing vehicle identified data pertaining to at least those mechanical components that match said one or more previously identified aberrant states on said at least one Internet connected server;

further receiving, on said at least one Internet connected server, said vehicle identity and status inquiry from a remote computerized device;

wherein in response to said inquiry, further using said at least one Internet connected server to associate said vehicle identity with those mechanical components that match one or more previously identified aberrant states, and transmitting information pertaining to those mechanical components that match said previously identified aberrant states, and information pertaining to said aberrant states, to said remote computerized device.

17. The method of claim 16, further using said at least one Internet connected server to transmit vehicle identified data pertaining to at least those mechanical components that match said one or more previously identified aberrant states, and said information pertaining to sad aberrant states, and a request for estimated repair costs to at least one computerized device associated with vehicle repair or insurance functions;

receiving said estimated repair costs or insurance authorization from said at least one remote computerized device associated with vehicle repair functions;

storing said estimated repair costs or insurance authorization in a repair database;

wherein when said at least one Internet connected server receives said vehicle identity and status inquiry from said at least one remote computerized device, further transmitting information pertaining to said estimated repair costs or insurance authorization to said remote computerized device.

18. The method of claim 15, wherein when at least some of said vehicle'"'"'s plurality of mechanical components are operating, at least some of these operating components are subject to vibration or motions or sound or heat changes, and said computer database of comparative 3D scan data further comprises vibration or motion or sound or heat change data of operating components of said similar or identical vehicles in both ideal and identified aberrant states;

wherein said 3D scanner output data further comprises information pertaining to vibrations or motions or sound or heat changes in at least some of said operating components;

further using said at least one computer processor to determine differences between said vibration or motion or sound or heat change data and said computer database comparative 3D scan data, and further determining if said vibration or motion or sound or heat change data further identifies if any of said mechanical components match said vibration or motion or sound or heat change data identified aberrant status.

19. The method of claim 15, wherein at least some of said plurality of components comprise engine components, and said previously identified aberrant states provides information pertaining to a maintenance status of said engine components.