Laser tracker used with six degree-of-freedom probe having separable spherical retroreflector

• US 8,902,408 B2
• Filed: 04/23/2012
• Issued: 12/02/2014
• Est. Priority Date: 02/14/2011
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Bridges, Robert E.
• Primary Examiner(s): Ratcliffe, Luke
• Assistant Examiner(s): Abraham, Samantha K
• Application Number:
  US13/453,002
• Publication Number:
  US 20130155386A1
• Time in Patent Office: 953 Days
• Field of Search: 356/3.01, 356/4.01, 356/5.01, 356/9, 356/625, 342/5, 342/61, 342/73, 342/118, 342/140, 342/147, 342/156, 367/13, 367/21, 367/27, 367/28, 367/64, 367/118
• US Class Current: 356/4.01
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/03 by measuring coordinates of points
• CPC Class Codes: G01B 5/004 for measuring coordinates of points
• CPC Class Codes: G01C 15/002 Active optical surveying means optical plumbing G01C15/105
• CPC Class Codes: G01C 15/06 Surveyors' staffs; Movable markers
• CPC Class Codes: G01S 17/42 Simultaneous measurement of distance and other co-ordinates indirect measurement G01S17/46
• CPC Class Codes: G01S 17/66 Tracking systems using electromagnetic waves other than radio waves
• CPC Class Codes: G01S 17/74 Systems using reradiation of electromagnetic waves other than radio waves, e.g. IFF, i.e. identification of friend or foe
• CPC Class Codes: G01S 7/48 of systems according to group G01S17/00
• CPC Class Codes: G01S 7/4818 using optical fibres
• CPC Class Codes: G01S 7/497 Means for monitoring or calibrating
• CPC Class Codes: G02B 5/122 cube corner, trihedral or triple reflector type
• CPC Class Codes: G02B 5/132 with individual reflector mounting means

Abstract

A method for measuring three-dimensional coordinates of a probe center includes: providing a spherically mounted retroreflector; providing a probe assembly; providing an orientation sensor; providing a coordinate measurement device; placing the spherically mounted retroreflector on the probe head; directing the first beam of light from the coordinate measurement device to the spherically mounted retroreflector; measuring the first distance; measuring the first angle of rotation; measuring the second angle of rotation; measuring the three orientational degrees of freedom based at least in part on information provided by the orientation sensor; calculating the three-dimensional coordinates of the probe center based at least in part on the first distance, the first angle of rotation, the second angle of rotation, and the three orientational degrees of freedom; and storing the three-dimensional coordinates of the probe center.

Claims

1. A method for measuring three-dimensional coordinates of a first point and a second point, the method comprising:

providing a spherically mounted retroreflector, the spherically mounted retroreflector including a retroreflector mounted in a retroreflector body, the retroreflector body having a first spherical shape over a first portion of its outer surface, the first portion having a target center, the retroreflector configured to receive a first beam of light and to return a second beam of light, the second beam of light being a portion of the first beam of light, the second beam of light traveling in a direction substantially opposite the direction of the first beam of light;

providing a probe assembly, the probe assembly including a probe stylus and a probe head, the probe stylus including a probe tip, the probe tip having a second spherical shape over a second portion of its surface, the second portion having a probe center, the probe head configured to receive the spherically mounted retroreflector and to permit rotation of the spherically mounted retroreflector about the target center while keeping the target center at a substantially constant position relative to the probe assembly;

providing a coordinate measurement device, the coordinate measurement device including a first motor, a second motor, a first angle measuring device, a second angle measuring device, a distance meter, a position detector, a control system, an orientation sensor, and a processor,

the first motor and the second motor configured together to direct the first beam of light to a first direction, the first direction determined by a first angle of rotation about a first axis and a second angle of rotation about a second axis, the first angle of rotation produced by the first motor and the second angle of rotation produced by the second motor,

the first angle measuring device configured to measure the first angle of rotation and the second angle measuring device configured to measure the second angle of rotation,

the distance meter configured to measure a first distance from the coordinate measurement device to the spherically mounted retroreflector based at least in part on a third portion of the second beam of light received by a first optical detector,

the position detector configured to produce a first signal in response to a position of a fourth portion of the second beam of light on the position detector,

the control system configured to send a second signal to the first motor and a third signal to the second motor, the second signal and the third signal based at least in part on the first signal, the control system configured to adjust the first direction of the first beam of light to the position in space of the spherically mounted retroreflector,

the orientation sensor configured to measure three orientational degrees of freedom of the probe assembly,

the processor configured to determine three-dimensional coordinates of the probe center, the three-dimensional coordinates based at least in part on the first distance, the first angle of rotation, the second angle of rotation, and the three orientational degrees of freedom;

placing the spherically mounted retroreflector on the probe head;

moving the probe center to the first point;

directing the first beam of light from the coordinate measurement device to the spherically mounted retroreflector;

measuring the first distance;

measuring the first angle of rotation;

measuring the second angle of rotation;

measuring the three orientational degrees of freedom based at least in part on information provided by the orientation sensor;

determining a first set of three-dimensional coordinates of the probe center based at least in part on the first distance, the first angle of rotation, the second angle of rotation, and the three orientational degrees of freedom;

storing the first set of three-dimensional coordinates of the probe center;

removing the spherically mounted retroreflector from the probe head;

moving the target center to the second point after removing the spherically mounted retroreflector from the probe head;

directing the first beam of light from the coordinate measurement device to the spherically mounted retroreflector with the target center in the second point;

measuring a second distance with the target center in the second point;

measuring a third angle of rotation with the target center in the second point;

measuring a fourth angle of rotation with the target center in the second point;

determining a second set of three-dimensional coordinates of the target center based at least in part on the second distance, the third angle of rotation, and the fourth angle of rotation; and

storing the second set of three-dimensional coordinates of the target center.

2. The method of claim 1, wherein the step of placing the spherically mounted retroreflector on the probe head further includes placing the spherically mounted retroreflector into an indexed position.

3. The method of claim 2, wherein:

the step of providing a spherically mounted retroreflector further includes providing the spherically mounted retroreflector with a collar, the collar including indexing features;

the step of providing a probe assembly further includes providing the probe head with a mating structure, the mating structure having mating features; and

the step of placing the spherically mounted retroreflector on the probe head further includes moving the spherically mounted retroreflector into the indexed position by registering the indexing features with the mating features.

4. The method of claim 1, wherein the step of placing the spherically mounted retroreflector on the probe head further includes rotating the spherically mounted retroreflector relative to the probe head into a desired orientation without translating the target center.

5. The method of claim 4, wherein:

the step of providing a probe assembly further includes providing the probe head with a clamping device, the clamping device configured to hold the spherically mounted retroreflector in a fixed orientation; and

the step of placing the spherically mounted retroreflector further includes clamping the spherically mounted retroreflector into the desired orientation.

6. The method of claim 4, further includes the step of determining probe compensation parameters, the probe compensation parameters including at least information indicative of an orientation of the spherically mounted retroreflector in relation to the probe assembly.

7. The method of claim 6, wherein the step of determining probe compensation parameters further includes steps of:

providing a nest configured to accept the probe tip, the nest further configured to permit rotation of the probe tip about the probe center, the probe center held at a substantially fixed point in space;

placing the probe tip into the nest;

rotating the probe tip;

measuring a collection of quantities, the collection of quantities including the first distance, the first angle of rotation, the second angle of rotation, and the three orientational degrees of freedom, each of the measured values obtained for a plurality of different rotations of the probe tip; and

calculating the probe compensation parameters based at least in part on the collection of quantities.

8. The method of claim 1, further including steps of:

incorporating a pattern into the retroreflector;

providing an optical system including a lens and a photosensitive array, the lens configured to form an image of at least a portion of the patterned retroreflector on the photosensitive array;

converting the image into a digital data set; and

calculating the three orientational degrees of freedom based at least in part on the digital data set.

9. The method of claim 8, wherein, in the step of providing a spherically mounted retroreflector, the retroreflector is a glass cube-corner retroreflector.

10. The method of claim 1, wherein, in the step of providing the probe assembly, the probe assembly operates without the use of electrical power.

11. The method of claim 1, wherein the probe assembly includes an actuator button.

12. The method of claim 1, wherein in the step of providing the probe assembly the probe stylus is removed and is replaced by a second probe stylus.

13. The method of claim 1 wherein the step of placing the spherically mounted retroreflector on the probe head includes magnetically coupling the spherically mounted retroreflector to the probe head.