Method for finding a home reference distance using a spherically mounted retroreflector

• US 9,423,492 B2
• Filed: 12/11/2013
• Issued: 08/23/2016
• Est. Priority Date: 12/11/2013
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Bridges, Robert E.
• Primary Examiner(s): NGUYEN, SANG H
• Application Number:
  US14/102,921
• Publication Number:
  US 20150285903A1
• Time in Patent Office: 986 Days
• Field of Search: 356614-625, 356/3.01, 356/3.15, 356/4.01, 356/5.01, 356/5.15, 356/28, 356/28.5
• US Class Current: 1/1
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• 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 17/08 for measuring distance only indirect measurement G01S17/46; active triangulation systems G01S17/48
• CPC Class Codes: G01S 17/66 Tracking systems using electromagnetic waves other than radio waves
• CPC Class Codes: G01S 7/497 Means for monitoring or calibrating
• CPC Class Codes: G01S 7/4972 Alignment of sensor

Abstract

A method of finding a home reference distance of a 3D coordinate measurement device in which a mathematical adjustment is made to move the vertex point to the sphere center of a spherically mounted retroreflector (SMR).

Claims

1. A method for determining a home reference distance, the method comprising:

providing a spherically mounted retroreflector (SMR), the SMR including a body and a retroreflector, the SMR including a reference point, the body having a spherical exterior portion that has a sphere center and a sphere radius, the body containing a cavity, the cavity sized to hold the retroreflector, the cavity open to a region outside the body, the retroreflector at least partially disposed in the cavity, the retroreflector being an open-air cube-corner retroreflector, the retroreflector having a set of three mutually perpendicular planar reflectors that intersect in a set of three lines and in a common vertex point, the cavity including an air-filled region interior to reflecting surfaces of the set of three planar reflectors, the retroreflector having an axis of symmetry relative to the set of three lines, the SMR having an SMR runout plane perpendicular to the axis of symmetry and passing through the sphere center, the SMR having an SMR intersection point, the SMR intersection point being a point of intersection of the axis of symmetry with the SMR runout plane, the SMR having an error vector extending from the vertex point to the sphere center, the SMR error vector having an SMR depth error vector component and an SMR runout error vector component, the SMR depth error vector component being a vector that extends from the vertex point to the SMR intersection point, the SMR runout error vector component being a vector that extends from the SMR intersection point to the sphere center, the SMR depth error vector component having a magnitude equal to an SMR depth error;

providing a three-dimensional (3D) coordinate measurement device including a base, a first motor, a second motor, a first angle measuring device, a second angle measuring device, a distance meter, a home position nest, and a processor, the 3D coordinate measurement device having a device frame of reference, the 3D coordinate measurement device configured to send an emitted beam of light to the SMR, the retroreflector returning a portion of the emitted beam as a reflected beam, the first motor and the second motor together directing the emitted beam in an emitted direction, the emitted 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 rotation of the first axis and the second axis made with respect to the base, the second axis having a rotation point lying on a line coinciding with the emitted beam, the first angle measuring device measuring the first angle of rotation and the second angle measuring device measuring the second angle of rotation, the distance meter measuring a target distance from the 3D coordinate measurement device to the retroreflector based at least in part on the reflected beam received by the 3D coordinate measurement device, the home position nest being affixed to the base and being configured to receive the spherical exterior portion;

providing a second nest and a third nest, the second nest and the third nest configured to repeatably receive the spherical exterior portion, the second nest having a second nest point corresponding to the sphere center when the SMR is in the second nest, the third nest having a third nest point corresponding to the sphere center when the SMR is in the third nest, a distance between the second nest point and the third nest point being a nest-to-nest distance, the second nest and the third nest having a nest center line, the nest center line being a line passing through the second nest point and the third nest point, the nest center line having an interior portion and an exterior portion, the interior portion being that portion of the nest center line between the second nest point and the third nest point, the exterior portion being the nest center line excluding the interior portion;

providing a processor and a memory;

providing a non-transitory computer readable media having computer readable instructions which when executed by the processor determines the home reference distance;

determining the SMR depth error;

recording the SMR depth error as a recorded data set;

reading by the processor the recorded data set;

placing the SMR in the home position nest;

sending from the 3D coordinate measurement device to the SMR in the home position nest a first emitted beam;

measuring with the 3D coordinate measurement device a first target distance to the SMR in the home position nest;

placing the rotation point of the 3D coordinate measurement device on the interior portion;

placing the SMR in the second nest;

sending from the 3D coordinate measurement device to the SMR in the second nest a second emitted beam;

measuring with the 3D coordinate measurement device a second target distance to the SMR in the second nest;

placing the SMR in the third nest;

sending from the 3D coordinate measurement device to the SMR in the third nest a third emitted beam;

measuring with the 3D coordinate measurement device a third target distance to the SMR in the third nest;

executing by the processor the computer readable instructions, the computer readable instructions performing calculations to determine the home reference distance, the home reference distance being a distance from the rotation point to the sphere center of the SMR in the home position nest, the home reference distance based at least in part on the nest-to-nest distance, the first target distance, the second target distance, the third target distance, and the SMR depth error; and

storing the home reference distance.

2. The method of claim 1 wherein:

the method further includes providing for the 3D coordinate measurement device a preferred home angle, the preferred home angle being an angle between the axis of symmetry and the first emitted beam;

the step of placing the SMR in the home position nest further includes placing the SMR into the home position nest at the preferred home angle;

the step of placing the SMR in the second nest further includes aligning the axis of symmetry to the second emitted beam; and

the step of placing the SMR in the third nest further includes aligning the axis of symmetry to the third emitted beam.

3. The method of claim 2 wherein:

the method further includes determining the SMR runout error vector component; and

the step of recording the SMR depth error as a recorded data set further includes recording a numerical representation of the SMR runout error vector component in the recorded data set.

4. The method of claim 3 wherein:

in the step of placing the SMR in the home position nest, the SMR is placed in a home orientation based at least in part on a home rule, the home rule being a rule for orienting the SMR in the home position nest, the home orientation being indicative of a position of the reference point relative to the axis of symmetry in the device frame of reference; and

in the step of executing by the processor the computer readable instructions, the home reference distance is further based on the numerical representation of the SMR runout error vector component, the home orientation, and the preferred home angle.

5. The method of claim 3 wherein:

in the step of providing a three-dimensional (3D) coordinate measurement device, the 3D coordinate measurement device further includes a camera, the camera having a photosensitive array and a lens, the lens having a focal length, the camera having a first distance between the lens and the photosensitive array, the first distance being selected, based at least in part on the focal length, to bring a mark on the SMR into focus on a first image when the SMR is placed in the home position nest, the first image being an image on the photosensitive array;

the method further includes determining a home orientation of the SMR based at least in part on the first image, the home orientation being indicative of a position of the reference point relative to the axis of symmetry in the device frame of reference; and

in the step of executing by the processor the computer readable instructions, the home reference distance is further based on the numerical representation of the SMR runout error vector component, the home orientation, and the preferred home angle.

6. The method of claim 1 further includes steps of:

placing the rotation point of the 3D coordinate measurement device on the exterior portion;

placing the SMR in the second nest;

sending from the 3D coordinate measurement device to the SMR in the second nest a fourth emitted beam;

measuring with the 3D coordinate measurement device a fourth target distance to the SMR in the second nest;

placing the SMR in the third nest;

sending from the 3D coordinate measurement device to the SMR in the third nest a fifth emitted beam;

measuring with the 3D coordinate measurement device a fifth target distance to the SMR in the third nest; and

determining the nest-to-nest distance based at least in part on the fourth target distance and the fifth target distance.

7. A method for determining a home reference distance, the method comprising:

providing a first spherically mounted retroreflector (SMR), the first SMR including a first body and a first retroreflector, the first SMR including a first reference point, the first body having a first spherical exterior portion that has a first sphere center and a first sphere radius, the first body containing a first cavity, the first cavity sized to hold the first retroreflector, the first cavity open to a first region outside the body, the first retroreflector at least partially disposed in the first cavity, the first retroreflector being an open-air cube-corner retroreflector, the first retroreflector having a first set of three mutually perpendicular planar reflectors that intersect in a first set of three lines and in a common first vertex point, the first cavity including a first air-filled region interior to reflecting surfaces of the first set of three planar reflectors, the first retroreflector having a first axis of symmetry relative to the first set of three lines, the first SMR having a first SMR runout plane perpendicular to the first axis of symmetry and passing through the first sphere center, the first SMR having a first SMR intersection point, the first SMR intersection point being a first point of intersection of the first axis of symmetry with the first SMR runout plane, the first SMR having a first error vector extending from the first vertex point to the first sphere center, the first SMR error vector having a first SMR depth error vector component and a first SMR runout error vector component, the first SMR depth error vector component being a vector that extends from the first vertex point to the first SMR intersection point, the first SMR runout error vector component being a vector that extends from the first SMR intersection point to the first sphere center, the first SMR depth error vector component having a magnitude equal to a first SMR depth error;

providing a second SMR, the second SMR including a second body and a second retroreflector, the second SMR including a second reference point, the second body having a second spherical exterior portion that has a second sphere center and a second sphere radius, the second body containing a second cavity, the second cavity sized to hold the second retroreflector, the second cavity open to a second region outside the second body, the second retroreflector at least partially disposed in the second cavity, the second retroreflector being an open-air cube-corner retroreflector, the second retroreflector having a second set of three mutually perpendicular planar reflectors that intersect in a second set of three lines and in a common second vertex point, the second cavity including a second air-filled region interior to reflecting surfaces of the second set of three planar reflectors, the second retroreflector having a second axis of symmetry relative to the second set of three lines, the second SMR having a second SMR runout plane perpendicular to the second axis of symmetry and passing through the second sphere center, the second SMR having a second SMR intersection point, the second SMR intersection point being a second point of intersection of the second axis of symmetry with the second SMR runout plane, the second SMR having a second error vector extending from the second vertex point to the second sphere center, the second SMR error vector having a second SMR depth error vector component and a second SMR runout error vector component, the second SMR depth error vector component being a vector that extends from the second vertex point to the second SMR intersection point, the second SMR runout error vector component being a vector that extends from the second SMR intersection point to the second sphere center, the second SMR depth error vector component having a magnitude equal to a second SMR depth error;

providing a third SMR, the third SMR including a third body and a third retroreflector, the third SMR including a third reference point, the third body having a third spherical exterior portion that has a third sphere center and a third sphere radius, the third body containing a third cavity, the third cavity sized to hold the third retroreflector, the third cavity open to a third region outside the third body, the third retroreflector at least partially disposed in the third cavity, the third retroreflector being an open-air cube-corner retroreflector, the third retroreflector having a third set of three mutually perpendicular planar reflectors that intersect in a third set of three lines and in a common third vertex point, the third cavity including a third air-filled region interior to reflecting surfaces of the third set of three planar reflectors, the third retroreflector having a third axis of symmetry relative to the third set of three lines, the third SMR having a third SMR runout plane perpendicular to the third axis of symmetry and passing through the third sphere center, the third SMR having a third SMR intersection point, the third SMR intersection point being a third point of intersection of the third axis of symmetry with the third SMR runout plane, the third SMR having a third error vector extending from the third vertex point to the third sphere center, the third SMR error vector having a third SMR depth error vector component and a third SMR runout error vector component, the third SMR depth error vector component being a vector that extends from the third vertex point to the third SMR intersection point, the third SMR runout error vector component being a vector that extends from the third SMR intersection point to the third sphere center, the third SMR depth error vector component having a magnitude equal to a third SMR depth error;

providing a three-dimensional (3D) coordinate measurement device including a base, a first motor, a second motor, a first angle measuring device, a second angle measuring device, a distance meter, a home position nest, and a processor, the 3D coordinate measurement device having a device frame of reference, the 3D coordinate measurement device configured to send an emitted beam of light to a target SMR, the target SMR including a target body and a target retroreflector the target retroreflector returning a portion of the emitted beam as a reflected beam, the first motor and the second motor together directing the emitted beam in an emitted direction, the emitted 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 rotation of the first axis and the second axis made with respect to the base, the second axis having a rotation point lying on a line coinciding with the emitted beam, the first angle measuring device measuring the first angle of rotation and the second angle measuring device measuring the second angle of rotation, the distance meter measuring a target distance from the 3D coordinate measurement device to the target retroreflector based at least in part on the reflected beam received by the 3D coordinate measurement device, the home position nest being affixed to the base and being configured to hold the target SMR;

providing a second nest and a third nest, the second nest configured to repeatably receive the second spherical exterior portion, the second nest having a second nest point corresponding to the second sphere center of the second SMR when the second SMR is placed in the second nest, the third nest configured to repeatably receive the third spherical exterior portion, the third nest having a third nest point corresponding to the third sphere center of the third SMR when the third SMR is placed in the third nest, a distance between the second nest point and the third nest point being a nest-to-nest distance, the second nest and the third nest having a nest center line, the nest center line being a line passing through the second nest point and the third nest point, the nest center line having an interior portion and an exterior portion, the interior portion being that portion of the nest center line between the second nest point and the third nest point, the exterior portion being the nest center line excluding the interior portion;

providing a processor and a memory;

providing a non-transitory computer readable media having computer readable instructions which when executed by the processor determines the home reference distance;

determining the first SMR depth error;

determining the second SMR depth error;

determining the third SMR depth error;

recording, in a recorded data set, the first SMR depth error, the second SMR depth error, and the third SMR depth error;

reading by the processor the recorded data set;

placing the first SMR in the home position nest;

sending from the 3D coordinate measurement device to the first SMR a first emitted beam;

measuring with the 3D coordinate measurement device a first target distance to the first SMR;

placing the rotation point of the 3D coordinate measurement device on the interior portion;

placing the second SMR in the second nest;

sending from the 3D coordinate measurement device to the second SMR a second emitted beam;

measuring with the 3D coordinate measurement device a second target distance to the second SMR;

placing the third SMR in the third nest;

sending from the 3D coordinate measurement device to the third SMR a third emitted beam;

measuring with the 3D coordinate measurement device a third target distance to the third SMR;

executing by the processor the computer readable instructions, the computer readable instructions performing calculations to determine the home reference distance, the home reference distance being a distance from the rotation point to the first sphere center of the first SMR in the home position nest, the home reference distance based at least in part on the nest-to-nest distance, the first target distance, the second target distance, the third target distance, the first SMR depth error, the second SMR depth error, and the third SMR depth error; and

storing the home reference distance.

8. The method of claim 7 wherein:

the method further includes providing for the 3D coordinate measurement device a preferred home angle, the preferred home angle being an angle between the first axis of symmetry and the first emitted beam;

the step of placing the first SMR in the home position nest further includes placing the first SMR into the home position nest at the preferred home angle;

the step of placing the second SMR in the second nest further includes aligning the second axis of symmetry to the second emitted beam; and

the step of placing the third SMR in the third nest further includes aligning the third axis of symmetry to the third emitted beam.

9. The method of claim 8 wherein:

the method further includes determining the first SMR runout error vector component; and

the step of recording the first SMR depth error as a recorded data set further includes recording a numerical representation of the first SMR runout error vector component in the recorded data set.

10. The method of claim 9 wherein:

in the step of placing the first SMR in the home position nest, the SMR is placed in a home orientation based at least in part on a home rule, the home rule being a rule for orienting the first SMR in the home position nest, the home orientation being indicative of a position of the first reference point relative to the first axis of symmetry in the device frame of reference; and

in the step of executing by the processor the computer readable instructions, the home reference distance is further based on the numerical representation of the first SMR runout error vector component, the home orientation, and the preferred home angle.

11. The method of claim 9 wherein:

in the step of providing a three-dimensional (3D) coordinate measurement device, the 3D coordinate measurement device further includes a camera, the camera having a photosensitive array and a lens, the lens having a focal length, the camera having a first distance between the lens and the photosensitive array, the first distance being selected, based at least in part on the focal length, to bring a mark on the first SMR into focus on a first image when the first SMR is placed in the home position nest, the first image being an image on the photosensitive array;

the method further includes determining a home orientation of the first SMR based at least in part on the first image, the home orientation being indicative of a position of the reference point relative to the axis of symmetry in the device frame of reference; and

in the step of executing by the processor the computer readable instructions, the home reference distance is further based on the numerical representation of the first SMR runout error vector component, the home orientation, and the preferred home angle.

12. The method of claim 9, wherein in the step of determining the second SMR depth error, the second SMR depth error is equal to the first SMR depth error, the second SMR and the first SMR being the same SMR.

13. The method of claim 9 wherein, in the step of determining the third SMR depth error, the third SMR depth error is equal to the second SMR depth error, the first SMR, the second SMR, and the third SMR all being the same SMR.

14. A method for adjusting a distance meter by an offset distance, the method comprising:

providing a spherically mounted retroreflector (SMR), the SMR including a body and a retroreflector, the body having a spherical exterior portion that has a sphere center, the body containing a cavity, the cavity sized to hold the retroreflector, the cavity open to a region outside the body, the retroreflector at least partially disposed in the cavity, the retroreflector being an open-air cube-corner retroreflector, the retroreflector having a set of three mutually perpendicular planar reflectors that intersect in a set of three lines and in a common vertex point, the cavity including an air-filled region interior to reflecting surfaces of the set of three planar reflectors, the retroreflector having an axis of symmetry relative to the set of three lines, the SMR having an SMR runout plane perpendicular to the axis of symmetry and passing through the sphere center, the SMR having an SMR intersection point, the SMR intersection point being a point of intersection of the axis of symmetry with the SMR runout plane, the SMR having an error vector extending from the vertex point to the sphere center, the SMR error vector having an SMR depth error vector component, the SMR depth error vector component being a vector that extends from the vertex point to the SMR intersection point, the SMR depth error vector component having a magnitude equal to an SMR depth error;

providing a three-dimensional (3D) coordinate measurement device including a base, a first motor, a second motor, a first angle measuring device, a second angle measuring device, the distance meter, and a processor, the 3D coordinate measurement device configured to send an emitted beam of light to the SMR, the retroreflector returning a portion of the emitted beam as a reflected beam, the first motor and the second motor together directing the emitted beam of light to an emitted direction, the emitted 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 rotation of the first axis and the second axis made with respect to the base, the second axis having a rotation point lying on a line coinciding with the emitted beam, the first angle measuring device measuring the first angle of rotation and the second angle measuring device measuring the second angle of rotation, the distance meter measuring a target distance from the 3D coordinate measurement device to the retroreflector based at least in part on the reflected beam received by the 3D coordinate measurement device;

providing a first nest and a second nest, the first nest and the second nest configured to repeatably receive the spherical exterior portion, the first nest having a first nest point corresponding to the sphere center of the SMR when the SMR is placed in the first nest, the second nest having a second nest point corresponding to the sphere center of the SMR when the SMR is placed in the second nest, the distance between the first nest point and the second nest point being a nest-to-nest distance, the first nest and the second nest having a nest center line, the nest center line being a line passing through the first nest point and the second nest point, the nest center line having an interior portion and an exterior portion, the interior portion being that portion of the nest center line between the first nest point and the second nest point, the exterior portion being the nest center line excluding the interior portion;

providing a processor and a memory;

providing a non-transitory computer readable media having computer readable instructions which when executed by the processor determines the offset distance;

determining the SMR depth error;

recording the SMR depth error as a recorded data set;

reading by the processor the recorded data set;

placing the rotation point of the 3D coordinate measurement device on the interior portion;

placing the SMR in the first nest;

sending from the 3D coordinate measurement device to the SMR in the first nest a first emitted beam;

measuring with the 3D coordinate measurement device a first target distance to the SMR in the first nest;

placing the SMR in the second nest;

sending from the 3D coordinate measurement device to the SMR in the second nest a second emitted beam;

measuring with the 3D coordinate measurement device a second target distance to the SMR in the second nest;

executing by the processor the computer readable instructions, the computer readable instructions performing calculations to determine the offset distance, the offset distance based at least in part on the nest-to-nest distance, the first target distance, the second target distance, and the SMR depth error; and

measuring the target distance with the distance meter further based on the offset distance.

15. The method of claim 14 wherein:

the step of placing the SMR in the first nest further includes aligning the axis of symmetry to the first emitted beam; and

the step of placing the SMR in the second nest further includes aligning the axis of symmetry to the second emitted beam.

16. The method of claim 15 further comprising steps of:

placing the rotation point of the 3D coordinate measurement device on the exterior portion;

placing the SMR in the first nest;

sending from the 3D coordinate measurement device to the SMR in the first nest a third emitted beam;

measuring with the 3D coordinate measurement device a third target distance to the SMR in the first nest;

placing the SMR in the second nest;

sending from the 3D coordinate measurement device to the SMR in the second nest a fourth emitted beam;

measuring with the 3D coordinate measurement device a fourth target distance to the SMR in the second nest; and

determining the nest-to-nest distance further based on the third target distance and the fourth target distance.

17. The method of claim 14 further comprising steps of:

sending a first reference emitted beam to a reference target;

measuring with the 3D coordinate measurement device a first reference target distance to the reference target;

storing the first reference target distance;

sending a second reference emitted beam to the reference target; and

setting the distance meter to read a reset distance, wherein the reset distance is based at least in part on the first reference target distance.

18. The method of claim 17 wherein the reference target is a retroreflector attached to the base.

19. The method of claim 17 wherein the reference target is a mirror attached to the base.

20. The method of claim 17 wherein the reference target is a retroreflector internal to the 3D coordinate measurement device.

21. The method of claim 17 wherein the reference target is a fiber retroreflector.