Graphical re-inspection user setup interface

• US 10,074,057 B2
• Filed: 05/20/2005
• Issued: 09/11/2018
• Est. Priority Date: 05/21/2004
• Status: Active Grant

• Current Assignee: Pressco Technology Inc.
• Original Assignee: Pressco Technology Inc.
• Inventors: Cochran, Don W., Awig, II, Fredrick F., Batty, Kevin E., Booher, Jesse C., Cochran, David W., Gilliland, Patrick, Morgan, Jr., Noel E., Palombo, Thomas H., SirLouis, Timothy, Yoder, Michael L.
• Primary Examiner(s): Theriault, Steven B
• Application Number:
  US11/134,137
• Publication Number:
  US 20050273720A1
• Time in Patent Office: 4,862 Days
• Field of Search: 715764, 715751, 715736, 715866, 382141, 382149
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31472 Graphical display of process
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

The invention provides for a graphical user interface which provides for very simple and intuitive ways of changing single or multiple inspection parameters. The graphical display immediately shows what the monitoring or inspection result would have been if the effected change had been in place during the inspection of the last “N” parts. This retrospective graphical “look-back” invokes immediate re-inspection facilitating an estimation of what the future inspection or process monitoring results will be if future production looks similar to the recent past production. The re-inspection results are immediately shown with a combination of visualization for ease of understanding and settings optimization. The visualization also shows selected other associated data to each specific inspection for ease of tracking and optimizing production processes.

Claims

1. A system for use with a machine vision inspection system, the system comprising:

a graphical display device operative to provide a visualization of selected historical data on results of a machine vision inspection process, the selected historical data being stored in a storage device and including image data including images obtained and stored during the inspection process, wherein the visualization comprises a representation of a population of selected images, an indicator value of a measure of acceptability for each respective image and a corresponding element providing for selection and viewing of an inspected image of each respective sample; and

,

a controller for the inspection process having at least one threshold setting for a parameter of the inspection process, wherein an adjustment thereof comprises user manipulation of a graphical element and triggers re-inspection of the stored images within the selected historical data and changes the visualization of the results to indicate differing results of the inspection process based on the adjustment of the setting.

2. The system as set forth in claim 1 wherein the visualization is operative to trigger additional selected images or data to be displayed upon manipulation of a pointer or graphical actuator.

3. The system as set forth in claim 2 wherein additional selected data includes at least one of time, temperature information, color information, manufacturing path information, mass information, measurement information, identification information, batch information, pressure information, machinery settings information, and maintenance history information.

4. The system as set forth in claim 1 wherein the selection of the element comprises selecting a bar element of a bar graph to display at least one inspected image of a sample.

5. The system as set forth in claim 1 wherein the visualization is operative to display of a subset or superset of the selected historical data upon pointing to or selecting a graphical element.

6. The system as set forth in claim 1 wherein the selected historical data represents the population of images obtained during the inspection process and the system facilitates adjustment of machine vision inspection parameters while simultaneously viewing inspection results on a selected population of images.

7. The system as set forth in claim 6 wherein the visualization is a single visualization screen on the display device.

8. The system as set forth in claim 1 wherein the adjustment comprises use of sliders, mouse clicking, knobs or touch screens.

9. The system as set forth in claim 1 wherein the reinspection is shown in a subsequent visualization.

10. The system as set forth in claim 9 wherein the reinspection includes a re-calculation of sensor data and non-image data.

11. The system as set forth in claim 10 wherein the re-inspection comprises an immediate re-inspection based on at least one setting change on the graphical user interface.

12. The system as set forth in claim 1 wherein the inspection or monitoring process is an industrial on-line process.

13. The system as set forth in claim 12 wherein the changes facilitated by the graphical visualization invoke changes in the on-line inspection or process monitoring system.

14. The system as set forth in claim 13 wherein the on-line inspection or process monitoring systems includes multiple channels.

15. The system as set forth in claim 14 wherein the multiple channels comprise connected, independent inspection or process monitoring stations or nodes.

16. The system as set forth in claim 12 wherein the graphical visualization is used for at least one of the following actions:

1) evaluation,

     2) making further adjustments, or

     3) invoking changes in the inspection or process monitoring system.

17. The system as set forth in claim 16 wherein a further action is taken to accept the invoking of the changes.

18. The system as set forth in claim 17 wherein a final acceptance of the changes in the inspection system is security protected.

19. The system as set forth in claim 12 wherein the visualization of the historical data is a visualization of relevant indicators relating to a measured product or process parameter being monitored.

20. The system as set forth in claim 19 wherein the visualization further includes the concurrent visualization of multiple selected control limit settings.

21. The system as set forth in claim 19 wherein the visualization of historical data is a visualization of related or correlated information to respective historical samples.

22. The system as set forth in claim 21 wherein the correlated information includes at least one of process controlled machine parts, molds, fixtures, or process elements that effect the process.

23. The system as set forth in claim 19 wherein the visualization further includes the visualization of at least one selected control limit setting.

24. The system as set forth in claim 1 wherein the historical data includes saved data stored in at least one of a solid-state digital memory, rotating memory, optical memory or other computer storage media.

25. The system as set forth in claim 24 wherein the historical data includes non-image forms of raw sensor data relating to indicator values of the measured product or process parameters shown by the visualization.

26. The system as set forth in claim 1 wherein the visualization comprises a bar graph representing a population of selected historical samples.

27. The system as set forth in claim 26 wherein a height of each respective bar is an indicator value of a measure of badness or goodness computed by the system for each respective sample.

28. The system as set forth in claim 26 wherein the bar graph includes bar elements having colors which are indicative of a selected characteristic or a display of information relating to the bar elements.

29. The system as set forth in claim 1 wherein the selected historical data represents a predetermined sampling of data corresponding to parts or events being inspected or monitored.

30. The system as set forth in claim 29 wherein the predetermined sampling comprises at least one of time-based sampling, count-based sampling, periodic sampling, event-based sampling, sampling plan theory based sampling, shift-based sampling, random-based sampling, algorithm-based sampling, military-based sampling, frequency-based sampling, percent-based sampling, location-based sampling, station-based sampling, and manufacturing path based sampling.

31. The system as set forth in claim 1 wherein the visualization shows a selected mix of samples from production wherein the selected mix of samples from production represents a comparison of a first type of selected samples with at least a second type of selected samples.

32. The system as set forth in claim 31 wherein the first type comprises samples having a particular characteristic.

33. The system as set forth in claim 31 wherein the second type comprises samples obtained using at least one of time-based sampling, count-based sampling, periodic sampling, event-based sampling, sampling plan theory based sampling, shift-based sampling, random-based sampling, algorithm-based sampling, military-based sampling, frequency-based sampling, percent-based sampling, location-based sampling, station-based sampling, and manufacturing path based sampling.

34. The system as set forth in claim 31 wherein the second type comprises samples having a particular characteristic.

35. The system as set forth in claim 1 wherein the visualization results are expressed in terms specifically useful to a user.

36. The system as set forth in claim 35 wherein the terms are defined as at least one of dimension, mass, percentage, monetary impact, measurement, visual attribute and numbers of parts.

37. The system as set forth in claim 1 wherein the at least one threshold setting comprises a sensitivity level and a defect scale.

38. The system as set forth in claim 1 wherein the visualization includes a holographic image display.

39. The system as set forth in claim 1 wherein visualization of specific defect types is in a form of a holographic display.

40. A system comprising:

a graphical display device operative to provide a visualization of historical data on results of a machine vision inspection process, the historical data being stored in a storage device and including image data including images obtained and stored during the inspection process, wherein the visualization comprises a bar graph representing a population of selected images, wherein a height of each respective bar is an indicator value of a measure of goodness or badness computed for each image and wherein each respective bar is selectable to view an inspected image; and

,

a controller for the inspection process having at least one threshold setting for a parameter of the inspection process wherein an adjustment thereof comprises user manipulation of a graphical threshold on the graphical display device and triggers re-inspection of the stored images of the historical data, changes the visualization to indicate differing results of the inspection process to reflect the adjustment, and selectively changes parameters of the inspection or monitoring process.

41. A method comprising:

displaying historical data in a graphical user interface on a graphical display device to provide a visualization of results of an inspection process, wherein the visualization comprises a representation of a population of selected images obtained and stored during the inspection process, an indicator value of a measure of acceptability for each image and a corresponding element providing for selection and viewing of an inspected image; and

,

changing, by a controller, the visualization to indicate differing results of the inspection process to reflect a re-inspection of the images obtained during the inspection process, triggered by an adjustment of at least one threshold setting for a parameter of the inspection process through user manipulation of a graphical element of the graphical user interface on the graphical display device.

42. A method used in a process or monitoring system, the method comprising:

displaying selected historical data in a graphical user interface on a graphical display device to provide a visualization of results of an inspection process, wherein the visualization comprises a bar graph representing a population of selected images, wherein a height of each respective bar is an indicator value of a measure of goodness or badness computed for each image and wherein each respective bar is selectable to view an inspected image; and

,

changing, by a controller, the visualization to indicate differing results of the inspection or monitoring process to reflect a re-inspection of the images obtained during the inspection process, triggered by an adjustment of at least one threshold setting for a parameter of the inspection process through user manipulation of a graphical element of the graphical user interface on the graphical display device.

43. A system for use in a machine vision inspection system, the system comprising:

a display device operative to provide a single screen visualization of selected historical data on results of an on-line machine vision inspection process stored in a storage device, the selected historical data representing a population of inspected parts, and the selected historical data comprising images of selected regions of interest of the inspected parts obtained and stored during the inspection process, wherein the visualization comprises a bar graph representing a population of selected images, wherein a height of each respective bar is an indicator value of a measure of goodness or badness computed for each image and wherein each respective bar is selectable to view an inspected image; and

,

a controller for the on-line machine vision inspection process having at least one threshold setting for a parameter of the inspection process wherein an adjustment thereof comprises manipulation of a graphical threshold line or graphical element on the graphical display device and triggers re-inspection of the images and changes the single screen visualization and indicates differing results of the process to reflect the adjustment.

44. The system as set forth in claim 43 wherein the single screen visualization comprises an unwrapped view of a selected region of interest of a selected image of an inspected part.

45. The system as set forth in claim 43 wherein the images comprise a plurality of thumbnail images.