Method and apparatus for improved inspection and classification of attributes of a workpiece

• US 6,594,590 B2
• Filed: 07/05/2001
• Issued: 07/15/2003
• Est. Priority Date: 04/17/1998
• Status: Expired due to Term

• Current Assignee: Usnr/Kockums Cancar Company (USNR, LLC)
• Original Assignee: Coe Newnes/McGehee ULC (USNR, LLC)
• Inventors: McGuire, Michael, Johnson, Emeric, Ogloff, Harry, Skocic, Zvonimr, Woods, Steve C.
• Primary Examiner(s): ASSOUAD, PATRICK J
• Application Number:
  US09/900,095
• Publication Number:
  US 20020040283A1
• Time in Patent Office: 740 Days
• Field of Search: 702/35, 702/84, 702/81, 709/203, 709/315, 709/328, 703/7, 700/109, 700/110, 700/171, 700/159, 700/167, 250/559.25, 382/100
• US Class Current: 702/35
• CPC Class Codes: G01N 23/083 the radiation being X-rays
• CPC Class Codes: G01N 23/16 the material being a moving sheet or film
• CPC Class Codes: G01N 23/18 Investigating the presence of flaws defects or foreign matter
• CPC Class Codes: G07C 3/146 during manufacturing process

Abstract

An apparatus for detecting the probable existence, location, and type of defects in a workpiece is described. The apparatus includes a sensor subsystem, an optimizer, a control subsystem, and a computer system having a processor and computer readable memory. The sensor subsystem senses a first section of the workpiece and produces signals corresponding to a physical characteristic of the workpiece. The computer system is configured to generate a workpiece model based on the signals produced by the sensor subsystem. In an alternate embodiment, a defect assembler can be provided to merge signals front a plurality of sensor subsystems. The defect assembler can also be configured to generate the workpiece data model. The optimizer is configured to generate workpiece segmentation recommendations based on the workpiece data model.

Claims

1. A computer readable medium having computer-executable instructions for performing the following steps:

reading signals from a computer readable memory, the signals being representative of at least one physical characteristic of a first section of a workpiece;

reading a first workpiece section identifier from the computer readable memory, wherein the first workpiece section identifier specifically identifies the first workpiece section associated with the signals;

associating the signals for the first workpiece section to a first workpiece processing thread after receiving the associated workpiece section identifier;

generating a second workpiece processing thread for receiving signals from a second workpiece section; and

prior to the processing of the signals in the second workpiece processing thread, processing the signals in the first workpiece processing thread to generate a data model of the first workpiece section.

2. The computer readable medium of claim 1 further comprising computer-executable instructions for performing the following steps:

processing signals in the first workpiece processing thread to generate a data model of the second workpiece section;

combining the data model of the first workpiece section with the data model of the second workpiece section to generate an overall data model of the workpiece; and

deleting the second workpiece processing thread.

3. A method for generating a model of a workpiece, comprising:

reading signals from a computer readable memory, the signals being representative of at least one physical characteristic of a first section of a workpiece;

reading a first workpiece section identifier from the computer readable memory, wherein the first workpiece section identifier specifically identifies the first workpiece section associated with the signals;

associating the signals for the first workpiece section to a first workpiece processing thread after receiving the associated workpiece section identifier;

generating a second workpiece processing thread for receiving signals from a second workpiece section; and

prior to the processing of the signals in the second workpiece processing thread, processing the signals in the first workpiece processing thread to generate a data model of the first workpiece section.

4. The method of claim 3 further comprising the step of storing the data model on a computer readable medium.

5. In the method of claim 3 wherein the data model is generated as a digital data set, the method 37 further comprising the step of using the data model to generate a three-dimensional digital image of the workpiece.

6. In the method of claim 3 wherein the data model is generated as a digital data set, the method further comprising the steps of:

converting the data model to an analog data model; and

using the analog data model to generate an analog video image of the workpiece.

7. In the method of claim 3 wherein the data model is generated as a digital data set, the method further comprising the steps of:

generating an analog image of the workpiece;

digitizing the analog image of the workpiece;

combining the digitized analog image of the workpiece and the data model of the workpiece to generate an enhanced image of the workpiece; and

displaying the enhanced image of the workpiece.

8. In the method of claim 3 wherein the data model is generated as a digital data set, the method further comprising the steps of:

generating an analog image of the workpiece;

converting the data model to an analog data model;

combining the analog image of the workpiece and analog data model of the workpiece to generate an enhanced image of the workpiece; and

displaying the enhanced image of the workpiece.

9. A computer readable medium containing a data set representative of a model of a workpiece and defects associated with the workpiece, wherein the data set is generated by the steps comprising:

reading signals from a computer readable memory, the signals being representative of at least one physical characteristic of a first section of a workpiece;

reading a first workpiece section identifier from the computer readable memory, wherein the first workpiece section identifier specifically identifies the first workpiece section associated with the signals;

associating the signals for the first workpiece section to a first workpiece processing thread after receiving the associated workpiece section identifier;

generating a second workpiece processing thread for receiving signals from a second workpiece section;

prior to the processing of the signals in the second workpiece processing thread, processing the signals in the first workpiece processing thread to generate a data set representative of a model of the first workpiece section and defects associated with the first workpiece section; and

saving the data set on the computer readable medium.

10. The computer readable medium of claim 9 wherein the medium is configured to be portable.

11. A computer readable medium containing a data set representative of a model of a workpiece and defects associated with the workpiece, wherein the data set is generated by the steps comprising:

sensing a first section of the workpiece with a sensor system to produce signals corresponding to at least one physical characteristic of the first section of the workpiece;

storing the first workpiece section signals from the sensor system to a computer readable memory;

generating a workpiece data model of the first section of the workpiece with a computer using the first workpiece section signals from the computer readable memory;

generating a first defect assembler data subscription request with a defect assembler;

transmitting the first workpiece data model to a producer thread program contained within a computer which, in response to the receipt of the first workpiece data model, receives the first data subscription request from the defect assembler and transmits the first workpiece data model from the computer to the defect assembler via a first producer thread;

sensing a second section of the workpiece with the sensor system to produce signals corresponding to at least one physical characteristic of the second section of the workpiece;

storing the second workpiece section signals from the sensor system to the computer readable memory;

generating a second producer thread in response to storage of the second set of signals in the computer readable memory;

generating a workpiece data model of the second section of the workpiece with the computer using the second workpiece section signals from the computer readable memory;

generating a second defect assembler data subscription request with the defect assembler;

transmitting the second workpiece data model to the producer thread program which, in response to the receipt of the second workpiece data model, receives the second data subscription request from the defect assembler and transmits the second workpiece data model from the computer to the defect assembler;

within the defect assembler, generating a data set representative of a model of the workpiece and defects associated with the workpiece using the first and second workpiece data models; and

saving the data set on the computer readable medium.

12. The computer readable medium of claim 11 wherein the medium is configured to be portable.