Method and system for two-dimensional and three-dimensional inspection of a workpiece

• US 9,052,294 B2
• Filed: 05/31/2006
• Issued: 06/09/2015
• Est. Priority Date: 05/31/2006
• Status: Expired due to Fees

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Walton, Steven R.
• Primary Examiner(s): Roz, Mark
• Application Number:
  US11/421,273
• Publication Number:
  US 20070280501A1
• Time in Patent Office: 3,296 Days
• Field of Search: 382/100
• US Class Current: 1/1
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 2201/0626 Use of several LED's for spatial resolution
• CPC Class Codes: G01N 2201/0627 Use of several LED's for spectral resolution
• CPC Class Codes: G06T 2207/10152 Varying illumination
• CPC Class Codes: G06T 2207/30164 Workpiece; Machine component
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

A system and method for inspecting a workpiece are provided. According to one embodiment, the system includes a plurality of illumination sources positioned proximate to the workpiece and each operable to generate at least one respective illumination beam to illuminate at least a portion of the workpiece, wherein each beam has a different respective color. The system also includes at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece including the illumination beams incident thereon. In addition, the system includes a data system capable of providing simultaneous two-dimensional and three-dimensional information indicative of the workpiece based on the image acquired by the camera.

Claims

1. An inspection system for inspecting a moving workpiece, the system comprising:

a plurality of illumination sources positioned proximate to the workpiece and each operable to illuminate at least a portion of the workpiece with at least one respective illumination beam, each illumination beam having a different respective color;

at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece illuminated by the illumination beams; and

a data system capable of providing information indicative of the workpiece based on the image acquired by the camera;

wherein the plurality of illumination sources includes at least one LED array;

wherein the plurality of illumination sources further comprises at least one laser fan beam generator;

wherein the at least one laser fan beam generator is arranged to generate a laser beam at an oblique incidence angle, and thereby produce a line of laser light on the workpiece, the line being generally perpendicular to a direction of motion of the workpiece, and

the at least one LED array is arranged to generate a light wash on the surface of the moving workpiece; and

wherein the said information is two-dimensional and three-dimensional information, the two-dimensional information resulting from the illumination of the workpiece by the light wash, and the three-dimensional information resulting from the illumination of the workpiece by the laser fan beam.

2. The system according to claim 1, wherein the plurality of illumination sources produce respective illumination beams that are configured to illuminate a respective feature of the workpiece.

3. The system according to claim 1, wherein the incidence angle of the laser beam generated by the at least one laser fan beam generator is measured between a line drawn parallel to the workpiece and the laser beam.

4. The system according to claim 3, wherein the incidence angle is less than 30°

.

5. The system according to claim 1, wherein the data system is capable of providing at least one of information indicative of respective edges of the workpiece, a gap in the workpiece, a topology of the workpiece, a shape of the workpiece, and a potential flaw in the workpiece.

6. The system according to claim 1, wherein the data system is capable of providing the said information during processing of the workpiece.

7. A method for inspecting a moving workpiece, the method comprising:

illuminating at least a portion of the workpiece with a plurality of colored illumination beams;

capturing at least one image of at least a portion of the workpiece illuminated by the illumination beams;

and

providing information indicative of the workpiece based on the captured image;

wherein the said illuminating includes generating illumination using at least one LED array;

wherein said illuminating further comprises generating illumination using at least one laser fan beam generator;

wherein the at least one laser fan beam generator generates a laser beam at an oblique incidence angle, and thereby produces a line of laser light on the workpiece, the line being generally perpendicular to a direction of motion of the workpiece, and

the at least one LED array generates a light wash on the surface of the moving workpiece; and

wherein the said information is two-dimensional and three-dimensional information, the two-dimensional information resulting from the illumination of the workpiece by the light wash, and the three-dimensional information resulting from the illumination of the workpiece by the laser fan beam.

8. The method according to claim 7, further comprising performing a manufacturing process on the moving workpiece during the illuminating and capturing steps.

9. The method according to claim 7, wherein the incidence angle of the laser beam generated by the at least one laser fan beam generator is being measured between a line drawn parallel to the workpiece and the laser beam.

10. The method according to claim 9, wherein the incidence angle is less than 30°

.

11. The method according to claim 7, wherein the said providing comprises providing at least one of information indicative of respective edges of the workpiece, a gap in the workpiece, a topology of the workpiece, a shape of the workpiece, and a potential flaw in the workpiece.