Automated system and method for tracking and detecting discrepancies on a target object

• US 9,310,317 B2
• Filed: 01/25/2012
• Issued: 04/12/2016
• Est. Priority Date: 01/25/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Georgeson, Gary E., Troy, James J., Lea, Scott W.
• Primary Examiner(s): Kelley, Christopher S
• Assistant Examiner(s): Retallick, Kaitlin A
• Application Number:
  US13/357,768
• Publication Number:
  US 20130188059A1
• Time in Patent Office: 1,539 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/026 by measuring distance between sensor and object G01B11/0608 takes precedence
• CPC Class Codes: G01B 11/24 for measuring contours or curvatures
• CPC Class Codes: G01N 21/94 Investigating contamination, e.g. dust G01N21/85 takes precedence
• CPC Class Codes: G01N 21/9515 Objects of complex shape, e.g. examined with use of a surface follower device measuring contours and curvatures G01B11/24
• CPC Class Codes: G01N 21/952 Inspecting the exterior surface of cylindrical bodies or wires G01N21/956 takes precedence
• CPC Class Codes: G01S 17/875 for determining attitude

Abstract

A detection system including a target object having a target object coordinate system, a tracking unit configured to monitor a position and/or an orientation of the target object and generate a target object position signal indicative of the position and/or the orientation of the target object, a camera positioned to capture an image of the target object, an orienting mechanism connected to the camera to control an orientation of the camera relative to the target object, and a processor configured to analyze the image to detect a discrepancy in the image and, when the discrepancy is present in the image, determine a location of the discrepancy relative to the target object coordinate system based at least upon the target object position signal and the orientation of the camera, and then orient the camera and laser to aim at and point out the discrepancy.

Claims

1. A detection system comprising:

a target object having a target object coordinate system;

a tracking unit configured to monitor at least one of a position and an orientation of said target object and generate a target object position signal indicative of said at least one of said position and said orientation of said target object, wherein said target object is movable to a first target object position or orientation and a second target object position or orientation;

a camera configured to scan said target object and capture images of said target object;

an orienting mechanism connected to said camera to control an orientation of said camera relative to said target object; and

a processor configured to automatically;

adjust said orientation of said camera relative to said target object to scan, with said camera, one or more locations on said target object at said first target object position or orientation and said second target object position or orientation;

capture first images of first locations and second images of second locations on said target object at said first target object position or orientation and said second target object position or orientation, respectively;

select and retrieve first reference images of said target object associated with said first locations on said target object at said first target object position or orientation and second reference images of said target object associated with said second locations on said target object at said second target object position or orientation;

analyze each first image of said first images by comparing said first image to a corresponding first reference image of said first reference images and each second image of said second images by comparing said second image to a corresponding second reference image of said second reference images;

detect the presence, if any, of a first discrepancy in said first image as compared to said corresponding first reference image and a second discrepancy is said second image as compared to said corresponding second reference image; and

determine, when detected, a three-dimensional location of said first discrepancy and said second discrepancy relative to said target object coordinate system based at least upon said target object position signal at said first target object position or orientation and said second target object position or orientation, respectively, a position and said orientation of said camera, a pixel location of said first discrepancy in said first image, and a pixel location of said second discrepancy in said second image.

2. The detection system of claim 1 wherein said target object is mounted on a support structure and rotates relative to said support structure about an axis of rotation.

3. The detection system of claim 2 wherein said tracking unit comprises an encoder.

4. The detection system of claim 1 wherein said orienting mechanism is controllable by said processor.

5. The detection system of claim 1 wherein said orienting mechanism comprises a pan-tilt mechanism.

6. The detection system of claim 1 further comprising a memory, wherein said processor stores in said memory said location of said discrepancy as coordinate data.

7. The detection system of claim 6 wherein said reference images are stored in said memory.

8. The detection system of claim 1 further comprising a laser emitting device positioned to project a laser beam onto said target object.

9. The detection system of claim 8 wherein said laser emitting device is connected to said orienting mechanism such that said orienting mechanism controls an orientation of said laser emitting device relative to said target object.

10. The detection system of claim 9 wherein said orientation of said laser emitting device is controllable by said processor to project said laser beam onto said target object identifying a location of said discrepancy, when said discrepancy is detected.

11. The detection system of claim 8 wherein said laser emitting device is configured as a laser range meter.

12. The detection system of claim 1 further comprising a motion actuator coupled to said target object, said motion actuator being controllable by said processor to control at least one of said position and said orientation of said target object.

13. The detection system of claim 12 wherein said motion actuator comprises an electric motor.

14. A detection system comprising:

a target object having a target object coordinate system;

a motion actuator coupled to said target object to control at least one of a position and an orientation of said target object, wherein said target object is movable to a first target object position or orientation and a second target object position or orientation;

a tracking unit configured to monitor said at least one of said position and said orientation of said target object and generate a target object position signal indicative of said at least one of said position and said orientation of said target object;

a local positioning system instrument positioned relative to said target object, said local positioning system instrument comprising;

a camera configured to scan said target object and capture images of said target object;

and

an orienting mechanism connected to said camera to control an orientation of said camera; and

a processor configured to automatically;

adjust said orientation of said camera relative to said target object to scan one or more portions of said target object with said camera, when said target object is moved to said first target object position or orientation;

capture said images at different locations on said target object;

select and retrieve reference images of said target object associated with said different locations on said target object;

analyze each image of said images by comparing said image to a corresponding reference image of said reference images;

detect the presence, if any, of a discrepancy in said image as compared to said corresponding reference image;

determine a three-dimensional location of said discrepancy relative to said target object coordinate system based at least upon said target object position signal at said first target object position or orientation, said orientation of said camera, and a pixel location of said discrepancy in said image, when said discrepancy is detected in said image;

adjust said orientation of said camera relative to said target object to scan one or more portions of said target object with said camera, when said target object is moved to said second target object position or orientation;

capture additional images at additional different locations on said target object;

select and retrieve additional reference images of said target object associated with said additional different locations on said target object;

analyze each additional image of said additional images by comparing said additional image to a corresponding additional reference image of said additional reference images;

detect the presence, if any, of an additional discrepancy in said additional image as compared to said corresponding additional reference image;

determine a three-dimensional location of said additional discrepancy relative to said target object coordinate system based at least upon said target object position signal at said second target object position or orientation, said orientation of said camera, and a pixel location of said discrepancy in said image, when said additional discrepancy is detected in said additional image.

20. The detection system of claim 14 wherein said local positioning system instrument further comprises a laser emitting device configured to project a laser beam onto said target object and determine a distance between said target object and said local positioning system instrument, and wherein said processor is further configured to project said laser beam onto said discrepancy by controlling said orientation of said laser emitting device based on said location of said discrepancy relative to said target object coordinate system.

15. A method for detecting a discrepancy on a target object, said target object having a target object coordinate system, said method comprising the steps of:

providing a local positioning system instrument comprising a camera, and an orienting mechanism for controlling an orientation of said camera relative to said target object;

providing a motion actuator configured to selectively move said target object;

providing a tracking unit configured to monitor at least one of a position and an orientation of said target object;

determining at least one of an initial position and an initial orientation of said local positioning system instrument relative to said target object;

moving said target object to a first target object position or orientation;

automatically adjusting said orientation of said camera relative to said target object at said first target object position or orientation to scan one or more portions of said target object with said camera;

automatically capturing images of said target object at different locations on said target object;

automatically selecting and retrieving reference images of said target object associated with said different locations on said target object;

automatically comparing each image of said images to a corresponding reference image of said reference images;

automatically detecting the presence, if any, of a discrepancy in said image as compared to said reference image; and

automatically determining three-dimensional coordinates of said discrepancy in said target object coordinate system based at least upon said first target object position or orientation, said orientation of said camera corresponding to said image having said discrepancy, and a pixel location of said discrepancy in said image, when said discrepancy is present in said image;

moving said target object to a second target object position or orientation;

automatically adjusting said orientation of said camera relative to said target object at said second target object position or orientation to scan at least a portion of said target object with said camera;

automatically capturing additional images of said target object at additional different locations on said target object;

automatically selecting and retrieving additional reference images of said target object associated with said additional different locations on said target object;

automatically comparing each additional image of said additional images to a corresponding additional reference image of said additional reference images;

automatically detecting the presence, if any, of an additional discrepancy in said additional image as compared to said additional reference image; and

automatically determining three-dimensional coordinates of said additional discrepancy in said target object coordinate system based at least upon said second target object position or orientation, said orientation of said camera corresponding to said additional image having said additional discrepancy, and a pixel location of said additional discrepancy in said additional image, when said additional discrepancy is present in said additional image.

16. The method of claim 15 wherein said step of determining said three-dimensional coordinates comprises the steps of:

determining pixel locations of said discrepancy; and

converting said pixel locations into said three-dimensional coordinates.

17. The method of claim 15 further comprising the step of storing said three-dimensional coordinates in memory.

18. The method of claim 15 wherein said local positioning system instrument further comprises a laser emitting device, wherein said orienting mechanism controls an orientation of said laser emitting device relative to said target object, and further comprising the step of orienting said laser emitting device relative to said target object to project a laser beam onto said target object identifying a location of said discrepancy.

19. The method of claim 15 further comprising the step of activating an alarm when said discrepancy is present in said image.