Laser-based coordinate measuring device and laser-based method for measuring coordinates

• US 9,989,350 B2
• Filed: 10/06/2016
• Issued: 06/05/2018
• Est. Priority Date: 07/23/1999
• Status: Expired due to Term

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Bridges, Robert E., Brown, Lawrence B., West, James K., Ackerson, D. Scott
• Primary Examiner(s): LEE, HWA S
• Application Number:
  US15/287,336
• Publication Number:
  US 20170023352A1
• Time in Patent Office: 607 Days
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/02 for measuring length, width or thickness G01B11/08 takes precedence
• CPC Class Codes: G01B 11/026 by measuring distance between sensor and object G01B11/0608 takes precedence
• CPC Class Codes: G01B 11/03 by measuring coordinates of points
• CPC Class Codes: G01B 9/02012 using temporal intensity variation
• CPC Class Codes: G01C 3/08 Use of electric radiation detectors
• 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 5/163 Determination of attitude using inertial means G01C9/00; control of attitude G05D1/49

Abstract

A method for measuring a distance includes modulating the light beam at a first frequency, receiving a second beam by the optical detector to produce a first electrical signal having the first frequency and a first phase; modulating the light beam at a second frequency different than the first frequency; receiving the second beam by the optical detector to produce a second electrical signal having the second frequency and a second. After these steps, the retroreflector is moved while modulating the light beam continuously at the second frequency; and a first distance to the retroreflector is determined based at least in part on a the first and second frequencies and phases.

Claims

1. A method of steering a first laser beam from an instrument toward a first point on a first retroreflector, the method comprising:

providing the first retroreflector;

providing a three-dimensional (3D) measurement instrument having a first axis, a second axis, a first plane, a second plane, a first angle transducer, a second angle transducer, a position detector, a distance meter, and a first camera, the first camera including a first lens and a first photosensitive array, the first axis and the second axis substantially intersecting at a gimbal point, the first plane including the first axis and is perpendicular to the second axis, the second plane including the second axis, the first plane and the second plane intersecting in a first line, the instrument operable to rotate the first plane about the first axis and the second plane about the second axis, the position detector operable to intercept light reflected by the first retroreflector and to indicate a position of the intercepted light on the position detector, the distance meter operable to measure a distance from the gimbal point to the first point;

emitting from the instrument a cone of light along a third optical axis, the third optical axis operable to rotate about the first axis;

intercepting with the first retroreflector a first part of the cone of light to form a first region of light at the first retroreflector;

intercepting with the first lens a first portion of the cone of light reflected by the first retroreflector;

acquiring with the first photosensitive array a first image that includes an image of the first region;

determining a first position on the first photosensitive array of the image of the first region;

determining a first angular increment of the first plane and a second angular increment of the second plane based at least in part on the first image, wherein the first angular increment and the second angular increment are calculated to steer the first laser beam to the first point based at least in part on the determination of the first position;

rotating the first plane to a third angle to produce the first angular increment of the first plane and rotating the second plane to a fourth angle to produce the second angular increment of the second plane;

intercepting with the position detector a second portion of the first laser beam reflected by the first retroreflector;

rotating the first plane to a fifth angle and rotating the second plane to a sixth angle, the fifth angle and the sixth angle calculated to place the second portion at a predetermined location on the position detector;

measuring the fifth angle of rotation with the first angle transducer and measuring the sixth angle of rotation with the second angle transducer;

measuring a first distance with the distance meter; and

determining three-dimensional coordinates of the first point based at least in part on the fifth angle, the sixth angle, and the first distance.

2. The method of claim 1, further including a step of adjusting the first plane and second plane during movement of the first retroreflector to keep the second portion directed to the predetermined location on the position detector.

3. The method of claim 1, wherein the step of rotating the first plane to a third angle and rotating the second plane to a fourth angle to further includes steps of:

steering the first laser beam in a first pattern in space;

monitoring whether the second portion of the first laser beam reflected by the first retroreflector has been received by the position detector; and

stopping the steering of the first laser beam in the first pattern in response to the second portion being on the position detector.

4. The method of claim 3, wherein the step of rotating the first plane to a fifth angle and rotating the second plane to a sixth angle further includes a step of adjusting the first plane and second plane during movement of the first retroreflector to keep the second portion directed to the predetermined location on the position detector.

5. The method of claim 1, wherein, in the step of sending a cone of light, the direction of the cone of light is determined at least in part by the third angle.

6. The method of claim 1, wherein:

the step of providing the first retroreflector further includes a step of providing a second retroreflector, the second retroreflector having a second point;

intercepting with the second retroreflector a second part of the cone of light to form a second region of light at the second retroreflector;

the step of intercepting with the first lens a first portion of the cone of light reflected by the first retroreflector further includes a step of intercepting with the first lens a third portion of the cone of light, the third portion reflected by the second retroreflector;

in the step of obtaining a first image on the first photosensitive array, the first image further includes an image of the second region; and

the step of determining a first position further includes a step of determining and storing a second position, the second position being a position on the first photosensitive array of the image of the second region.

7. The method of claim 6, further including steps of:

calculating a third angular increment of the first plane and a fourth angular increment of the second plane, wherein the third angular increment and the fourth angular increment are calculated to steer the first laser beam to the second point;

rotating the first plane to a seventh angle to produce the third angular increment and rotating the second plane to an eighth angle to produce the fourth angular increment;

intercepting with the position detector a fourth portion of the first laser beam reflected by the second retroreflector;

rotating the first plane to a ninth angle and rotating the second plane to a tenth angle, the ninth angle and the tenth angle calculated to place the fourth portion at the predetermined location on the position detector;

measuring the ninth angle of rotation with the first angle transducer and measuring the tenth angle of rotation with the second angle transducer;

measuring a second distance with the distance meter; and

determining three-dimensional coordinates of the second point based at least in part on the ninth angle, the tenth angle, and the second distance.

8. The method of claim 1, wherein the predetermined position is located at the center of the position detector.

9. A system of steering a first laser beam, the system comprising:

a first retroreflector;

a 3D measurement instrument having a first axis, a second axis, a first plane, a second plane, a first angle transducer, a second angle transducer, a position detector, a distance meter, an electronics circuit and a first camera, the first camera including a first lens and a first photosensitive array, the first axis and the second axis substantially intersecting at a gimbal point, the first plane including the first axis and is perpendicular to the second axis, the second plane including the second axis, the first plane and the second plane intersecting in a first line, the instrument operable to rotate the first plane about the first axis and the second plane about the second axis, the position detector operable to intercept light reflected by the first retroreflector and to indicate a position of the intercepted light on the position detector, the distance meter operable to measure a distance from the gimbal point to the first point;

a computer operably coupled to the 3D measurement instrument, the computer cooperating with the electronics circuit to perform a method comprising;

emitting from the 3D measurement instrument a cone of light along a third optical axis, the third optical axis operable to rotate about the first axis;

intercepting with the first retroreflector a first part of the cone of light to form a first region of light at the first retroreflector;

intercepting with the first lens a first portion of the cone of light reflected by the first retroreflector;

acquiring with the first photosensitive array a first image that includes an image of the first region;

determining a first position on the first photosensitive array of the image of the first region;

determining a first angular increment of the first plane and a second angular increment of the second plane based at least in part on the first image, wherein the first angular increment and the second angular increment are calculated to steer the first laser beam to the first point based at least in part on the determination of the first position;

rotating the first plane to a third angle to produce the first angular increment of the first plane and rotating the second plane to a fourth angle to produce the second angular increment of the second plane;

intercepting with the position detector a second portion of the first laser beam reflected by the first retroreflector;

rotating the first plane to a fifth angle and rotating the second plane to a sixth angle, the fifth angle and the sixth angle calculated to place the second portion at a predetermined location on the position detector;

measuring the fifth angle of rotation with the first angle transducer and measuring the sixth angle of rotation with the second angle transducer;

measuring a first distance with the distance meter; and

determining three-dimensional coordinates of the first point based at least in part on the fifth angle, the sixth angle, and the first distance.

10. The system of claim 9, wherein the method further includes a step of adjusting the first plane and second plane during movement of the first retroreflector to keep the second portion directed to the predetermined location on the position detector.

11. The system of claim 9, wherein the step of rotating the first plane to a third angle and rotating the second plane to a fourth angle to further includes steps of:

steering the first laser beam in a first pattern in space;

monitoring whether the second portion of the first laser beam reflected by the first retroreflector has been received by the position detector; and

stopping the steering of the first laser beam in the first pattern in response to the second portion being on the position detector.

12. The system of claim 11, wherein the step of rotating the first plane to a fifth angle and rotating the second plane to a sixth angle further includes a step of adjusting the first plane and second plane during movement of the first retroreflector to keep the second portion directed to the predetermined location on the position detector.

13. The system of claim 9, wherein, in the step of sending a cone of light, the direction of the cone of light is determined at least in part by the third angle.

14. The system of claim 9, wherein:

the step of providing the first retroreflector further includes a step of providing a second retroreflector, the second retroreflector having a second point;

intercepting with the second retroreflector a second part of the cone of light to form a second region of light at the second retroreflector;

the step of intercepting with the first lens a first portion of the cone of light reflected by the first retroreflector further includes a step of intercepting with the first lens a third portion of the cone of light, the third portion reflected by the second retroreflector;

in the step of obtaining a first image on the first photosensitive array, the first image further includes an image of the second region; and

the step of determining a first position further includes a step of determining and storing a second position, the second position being a position on the first photosensitive array of the image of the second region.

15. The system of claim 14, wherein the method further including steps of:

calculating a third angular increment of the first plane and a fourth angular increment of the second plane, wherein the third angular increment and the fourth angular increment are calculated to steer the first laser beam to the second point;

rotating the first plane to a seventh angle to produce the third angular increment and rotating the second plane to an eighth angle to produce the fourth angular increment;

intercepting with the position detector a fourth portion of the first laser beam reflected by the second retroreflector;

rotating the first plane to a ninth angle and rotating the second plane to a tenth angle, the ninth angle and the tenth angle calculated to place the fourth portion at the predetermined location on the position detector;

measuring the ninth angle of rotation with the first angle transducer and measuring the tenth angle of rotation with the second angle transducer;

measuring a second distance with the distance meter; and

determining three-dimensional coordinates of the second point based at least in part on the ninth angle, the tenth angle, and the second distance.

16. The system of claim 9, wherein the predetermined position is located at the center of the position detector.