Geometric inspection of machined objects

• US 8,190,272 B2
• Filed: 12/16/2008
• Issued: 05/29/2012
• Est. Priority Date: 12/16/2008
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Crothers, Phillip John, Steele, Peter Nathan, Lam, Geoffrey King Shun
• Primary Examiner(s): Bahta, Kidest
• Application Number:
  US12/335,789
• Publication Number:
  US 20100153058A1
• Time in Patent Office: 1,260 Days
• Field of Search: 700/15, 700/194, 700/105, 700/98, 901/10, 901/41, 318/565, 318/612
• US Class Current: 700/15
• CPC Class Codes: B23Q 17/20 for indicating or measuring workpiece characteristics, e.g. contour, dimension, hardness
• CPC Class Codes: B23Q 17/24 using optics or electromagnetic waves
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 19/4065 Monitoring tool breakage, life or condition
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 19/4207 in which a model is traced or scanned and corresponding data recorded
• CPC Class Codes: G05B 2219/35159 With nominal blank and model in memory define tool path and machine workpiece
• CPC Class Codes: G05B 2219/36414 Compare image detected path with stored reference, difference corrects position
• CPC Class Codes: G05B 2219/36415 Adjust path and attitude tool by detecting path, line with a photosensor, laser
• CPC Class Codes: G05B 2219/36419 Compare modified, corrected path with stored reference, difference too large alarm
• CPC Class Codes: G05B 2219/37009 Calibration of vision system, camera, adapt light level
• CPC Class Codes: G05B 2219/37559 Camera, vision of tool, compute tool center, detect tool wear
• CPC Class Codes: G05B 2219/40623 Track position of end effector by laser beam
• CPC Class Codes: G05B 2219/45104 Lasrobot, welding robot
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method and apparatus may be present for inspecting an object. A plurality of locations associated with a plurality of operations performed by a tool on the object may be tracked. The plurality of locations is tracked while the plurality of operations is performed on the object. A path for the tool may be mapped using the plurality of locations to form a tool path. The tool path may be compared to a model of the object.

Claims

1. A method for inspecting an object during performance of an operation, the method comprising:

tracking a plurality of locations corresponding to a plurality of operations performed by a tool on the object, wherein the plurality of locations is tracked while the plurality of operations is performed on the object, by performing at least one of measuring a position of the tool with a metrology system to track a corresponding location of the each of the plurality of operations performed by the tool in order to form the plurality of locations, and measuring the position of the tool with a position sensor system used to move the tool in order to track the corresponding location of the each of the plurality of operations performed by the tool in order to form the plurality of locations, wherein the plurality of locations is a plurality of tracking tool center point locations;

generating a map of a path of the tool using the plurality of locations to form a tool path;

comparing the tool path to a model of the object to form a comparison, wherein the model is a final model of the object after the performance of the plurality of operations;

performing the plurality of operations on the object using the tool, wherein the plurality of operations is selected from at least one of a drilling operation, a trimming operation, a knurling operation, a milling operation, a boring operation, and a turning operation;

sending the plurality of locations to an analysis application on a computer, wherein creating and comparing are performed by the analysis application;

determining whether the path is within a tolerance from the model of the object using the comparison;

responsive to an absence of a determination that the path is within a threshold from the model of the object using the comparison, generating an alert; and

performing a number of actions on the object based on comparing the tool path to the model of the object, wherein the number of actions comprises at least one of halting performing the plurality of operations on the object using the tool if a selected number of locations is out of tolerance, flagging each corresponding location which is out of tolerance, and sending a message in response to the selected number of locations being out of tolerance, wherein the object is selected from one of a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a manufacturing facility, an engine, a frame, a spar, a part, a panel, a wheel, an engine case, a fan blade, and a building.

2. The method of claim 1, wherein tracking further comprises:

passively measuring the position of the tool with the position sensor system.

3. The method of claim 1, wherein tracking further comprises:

sending a laser beam from a 6-degree-of-freedom laser tracker onto a target attached to the tool; and

tracking the corresponding location of the each of the plurality of operations performed by the tool using a plurality of responses detected by the laser tracker.

4. A manufacturing environment comprising:

an analysis application configured to generate a map of a path of a tool using a plurality of locations from tracking a plurality of locations corresponding to a plurality of operations performed by a tool on the object, wherein the plurality of locations is tracked while the plurality of operations is performed on the object to form a tool path, and wherein the analysis application is further configured to compare the tool path to a model of the object, wherein the model is a final model of the object after the performance of the plurality of operations;

a data processing system, wherein the analysis application is located on the data processing system;

a tracking system configured to track a corresponding location of each of the plurality of operations to form the plurality of locations, wherein the tracking system comprises at least one of metrology system configured to measure a position of the tool with a sensor in order to track the corresponding location of the each of the plurality of operations performed by the tool in order to form the plurality of locations, and the position sensor system used to move the tool to track the corresponding location of the plurality of operations performed by the tool in order to form the plurality of locations, wherein the plurality of locations is a plurality of tracking tool center point locations; and

the tool, wherein the tool is selected from one of a computer numerical control machine, a lathe, a laser, a drill, an end mill, and a milling machine, and wherein the object is selected from one of a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a manufacturing facility, an engine, a frame, a spar, a part, a panel, a wheel, an engine case, a fan blade, and a building.

5. The manufacturing environment of claim 4, wherein the tracking system further comprises a passive tracking system.

6. The manufacturing environment of claim 4, wherein the data processing system is further configured to, responsive to an absence of a determination that the tool path is within a threshold from the final model of the object, generate an alert.

7. The manufacturing environment of claim 4, wherein the tracking system further comprises:

a 6-degree-of-freedom laser tracker configured to send a laser beam onto a target attached to the tool and wherein the tracking system is further configured to track the corresponding location of the each of the plurality of operations performed by the tool using a plurality of responses detected by the 6-degree-of-freedom laser tracker.

8. The manufacturing environment of claim 4, wherein the data processing system is configured to cause the tool to perform a number of actions on the object based on a comparison of the map to the final model of the object.

9. The manufacturing environment of claim 8, wherein the number of actions comprises at least one of halting performing the plurality of operations on the object using the tool if a selected number of locations is out of tolerance, flagging each location in which a particular location is out of tolerance, and sending a message in response to the selected number of locations being out of tolerance.

10. The manufacturing environment of claim 4, wherein the plurality of operations is selected from at least one of a drilling operation, a trimming operation , a knurling operation, a milling operation, a boring operation, and a turning operation.