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

• US 8,131,008 B2
• Filed: 01/30/2008
• Issued: 03/06/2012
• Est. Priority Date: 01/31/2007
• Status: Expired due to Fees

• Current Assignee: Building Component Verification Systems, Inc.
• Original Assignee: Building Component Verification Systems, Inc.
• Inventors: Thompson, Cyril Robert, Corley, Steven
• Primary Examiner(s): Rahmjoo, Mike
• Application Number:
  US12/012,016
• Publication Number:
  US 20080226122A1
• Time in Patent Office: 1,497 Days
• Field of Search: 382/100, 382/141, 382/152, 356/430, 356/431, 356/429, 493/374, 705/7, 703/1
• 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 that illuminates a portion of said pre-engineered structural component, said pre-engineered structural component comprising lumber and at least one support plate;

b) a camera that (i) receives a reflection of said light source from said pre-engineered structural component and (ii) generates an image output corresponding to said reflection;

c) a memory storage that stores at least one reference data, said at least one reference data corresponding to at least one reference structural component design;

d) a processing unit with an internal memory in communication with said light source, said camera, and said memory storage; and

e) programming in said processing unit that (i) receives said camera image output into internal memory, (ii) detects a characteristic of said pre-engineered structural component from said camera image output, said characteristic selected from the group of;

the presence of a lumber piece, the relative position of a lumber piece, the presence of a support plate, the relative position of a support plate, and combinations thereof, (iii) compares said characteristic to a corresponding characteristic of said at least one reference data, and (iv) provides a result of said comparison.

2. The system of claim 1, wherein said light source emits radiation having a narrow chromatic bandwidth.

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

4. The system of claim 1, wherein said camera receives radiation having a narrow chromatic bandwidth.

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

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

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

8. The system of claim 7, wherein said reflective surface is selected from the group consisting of a mirror and a prism.

9. The system of claim 7, further comprising (i) a first optical path from said pre-engineered structural component to said reflective surface and (ii) a second optical path from said reflective surface to said camera.

10. The system of claim 7, further comprising an enclosure for housing said light source, said reflective surface, and said camera.

11. The system of claim 7, further comprising a light source housing containing said light source and said reflective surface, said housing having a proximal opening and a distal opening.

12. The system of claim 11, wherein said light source housing has a uniform interior color.

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

14. The system of claim 1, further comprising an encoder that (i) detects the position of said pre-engineered structural component relative to said camera and (ii) generates output corresponding to said position.

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

16. The system of claim 1 wherein said processing unit compresses image output from said camera.

17. The system of claim 16 wherein said image compression configuration eliminates of backdrop areas of said image output.

18. The system of claim 16 wherein said processing unit saves compressed images.

19. The system of claim 1 wherein said pre-engineered structural component is a truss.

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

a. a light source that illuminates a portion of said pre-engineered structural component, said pre-engineered structural component comprising lumber and at least one support plate;

b. a camera that (i) receives a reflection of said light source from said pre-engineered structural component and (ii) generates an image output corresponding to said reflection;

c. a memory storage that stores at least one reference data, said at least one reference data corresponding to at least one reference structural component design;

d. a processing unit with an internal memory in communication with said light source, said camera, and said memory storage; and

e. programming in said processing unit that (i) receives said camera image output into internal memory, (ii) detects a characteristic 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, (iii) compares said characteristic to a corresponding characteristic of said at least one reference data, and (iv) provides a result of said comparison.

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

a) an emitter for projecting photons towards a portion of said pre-engineered structural component, said pre-engineered structural component comprising lumber and at least one support plate;

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

c) a processor in communication with said emitter, said receiver, and a program wherein said program (i) creates an electronic image of said pre-engineered structural component from said output, (ii) compares a characteristic of said image selected from the group of;

the presence of a lumber piece, the relative position of a lumber piece, the presence of a support plate, the relative position of a support plate, and combinations thereof to a corresponding characteristic of a reference image and (iii) provides a result of said comparison.

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

23. The apparatus of claim 21, further comprising an encoder for detecting the position of said pre-engineered structural component with respect to said receiver.

24. The apparatus of claim 21, further comprising a sensor for detecting an edge of the pre-engineered structural component.

25. The apparatus of claim 21, wherein said apparatus further comprises at least one reflective surface that creates (i) a first optical path from said pre-engineered 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.

26. The apparatus of claim 21 wherein said program compresses said electronic image.

27. The apparatus of claim 26 wherein said image compression program eliminates backdrop areas of said electronic image.

28. The apparatus of claim 26 wherein said processor unit saves compressed images in a memory storage.

29. The system of claim 21 wherein said pre-engineered structural component is a truss.

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

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

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

c) receiving reflections of said light source from said pre-engineered 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) selecting one of at least one reference array;

e) searching the data in said first array to find the presence and relative location of a characteristic selected from the group of;

at least one lumber piece, at least one support plate, and combinations thereof;

f) searching the data in said selected reference array to find the presence and relative location a corresponding characteristic selected from the group of;

at least one lumber piece, at least one support plate, and combinations thereof;

g) determining how closely the presence and relative location of said characteristic found in said first array corresponds to the presence and location of said corresponding characteristic found in said reference array; and

h) indicating a result of said determination.

31. The method of claim 30, comprising the further step of causing said light source to illuminate a second portion of said pre-engineered structural component.

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

33. The method of claim 30 further comprising the step of adjusting the data in said first array for skew.

34. The method of claim 30 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.

35. The method of claim 34 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.

36. The method of claim 30, 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.

37. The method of claim 30, 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.

38. The method of claim 37, 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.

39. The method of claim 30, wherein said indicating step comprises displaying a representation of said first array and a representation of said reference array on a monitor.

40. The method of claim 30, 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.

41. The method of claim 30 wherein said pre-engineered structural component is a truss.

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

a) a light source for illuminating a portion of said pre-engineered structural component, said pre-engineered structural component comprising lumber and at least one support plate;

b) a camera for receiving a reflection from said pre-engineered structural component and generating an image output corresponding to said reflection;

c) a memory 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 processor with a memory in communication with said light source, said camera and said memory, wherein said processor (i) receives said image output into said memory, (ii) detects a characteristic of said pre-engineered structural component from said image output wherein said characteristic is selected from the group of;

the presence of a lumber piece, the relative position of a lumber piece, the presence of a support plate, the relative position of a support plate, and combinations thereof, (iii) compares said characteristic to a corresponding characteristic of said at least one reference data, and (iv) provides a result of said comparison.

43. The system of claim 42 wherein said pre-engineered structural component is a truss.