Coordinate measurement machine with distance meter and camera to determine dimensions within camera images

• US 9,163,922 B2
• Filed: 11/20/2014
• Issued: 10/20/2015
• Est. Priority Date: 01/20/2010
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Bridges, Robert E., Parker, David H.
• Primary Examiner(s): GUADALUPE, YARITZA
• Application Number:
  US14/548,528
• Publication Number:
  US 20150075018A1
• Time in Patent Office: 334 Days
• Field of Search: 335/03, 335/02, 335/04, 335/56, 335/58, 335/59, 33/1.M, 33/1.PT
• US Class Current: 1/1
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/005 coordinate measuring machines
• CPC Class Codes: G01B 21/047 Accessories, e.g. for positioning, for tool-setting, for measuring probes
• CPC Class Codes: G01B 2210/58 Wireless transmission of information between a sensor or probe and a control or evaluation unit
• CPC Class Codes: G01B 5/008 using coordinate measuring machines
• CPC Class Codes: G01B 5/012 Contact-making feeler heads therefor
• CPC Class Codes: G05B 19/401 characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes G05B19/19 takes precedence
• CPC Class Codes: G05B 2219/37193 Multicoordinate measuring system, machine, cmm
• CPC Class Codes: G05B 2219/40233 Portable robot
• CPC Class Codes: G05B 2219/40555 Orientation and distance
• CPC Class Codes: G05B 2219/45061 Measuring robot

Abstract

An articulated arm coordinate measurement machine (AACMM) that includes a noncontact 3D measurement device, position transducers, a camera, and a processor operable to project a spot of light to an object point, to measure first 3D coordinates of the object point based on readings of the noncontact 3D measurement device and the position transducers, to capture the spot of light with the camera in a camera image, and to attribute the first 3D coordinates to the spot of light in the camera image.

Claims

1. A three-dimensional (3D) measuring device comprising:

an articulated arm coordinate measurement machine (AACMM), the AACMM including a base and a manually positionable arm portion having opposed first and second ends, the arm portion including a plurality of connected arm segments, each arm segment including at least one position transducer for producing a position signal, the first end attached to the base, a camera coupled to the second end, a non-contact 3D measurement device coupled to the second end, the noncontact 3D measurement device having a light source, the noncontact 3D measurement device configured to determine a distance to an object point based at least in part on the speed of light in air, and an electronic circuit which receives the position signal from the at least one position transducer and provides data corresponding to a position of the camera and the non-contact 3D measurement device; and

a processor system including at least one of an AACMM processor, an external computer, and a cloud computer configured for remote access, wherein the processor system is responsive to executable instructions which when executed by the processor system is operable to;

causing the light source to send a first beam of light to a first object point;

causing the noncontact 3D measurement device to receive a first reflected light and determine a first distance to the first object point in response, the first reflected light being a portion of the first beam of light reflected by the first object point;

determining an angle of the first beam of light relative to the AACMM based at least in part on first position signals from the at least one position transducer;

determining first 3D coordinates of the first object point based at least in part on the first distance and a first angle of the first beam of light relative to the AACMM;

causing the camera to obtain a first 2D image of a first surface, the first 2D image having a first spot of light caused by the first beam of light intersecting the first surface at the first object point; and

associating the first 3D coordinates to the first spot of light.

2. The 3D measuring device of claim 1 wherein the executable instructions further comprise determining a first dimension of a first feature in the first 2D image based at least in part on a first angular subtense of the first feature, the first distance, and a geometry of the first feature, wherein the first angular subtense is given with respect to a perspective center of the camera.

3. The 3D measuring device of claim 2 wherein the geometry of the first feature is one of a cylinder and a sphere, the first dimension being associated with a diameter of the cylinder and the sphere, respectively.

4. The 3D measuring device of claim 1 wherein the executable instructions further comprise:

causing the light source to send a second beam of light to a second object point;

causing the noncontact 3D measurement device to receive a second reflected light and determine a second distance to the second object point in response, the second reflected light being a portion of the second beam of light reflected by the second object point;

determining an angle of the second beam of light relative to the AACMM;

determining second 3D coordinates of the second object point based at least in part on the second distance and the second angle of the second beam of light relative to the AACMM; and

causing the camera to obtain a second 2D image of the first surface, the second 2D image having a second spot of light caused by the second beam of light intersecting the first surface at the second object point.

5. The 3D measuring device of claim 4 wherein the executable instructions further comprise:

causing the light source to send a third beam of light to a third object point;

causing the noncontact 3D measurement device to receive a third reflected light and determine a third distance to the third object point in response, the third reflected light being a portion of the third beam of light reflected by the third object point;

determining an angle of the third beam of light relative to the AACMM;

determining third 3D coordinates of the third object point based at least in part on the third distance and the third angle of the third beam of light relative to the AACMM; and

causing the camera to obtain a third 2D image of the first surface, the third 2D image having a third spot of light caused by the third beam of light intersecting the first surface at the third object point.

6. The 3D measuring device of claim 5 wherein the executable instructions further comprise determining when the first surface is a first plane shared by the first object point, the second object point, and the third object point, an equation for the first plane is based at least in part on the first 3D coordinates, the second 3D coordinates, and the third 3D coordinates.

7. The 3D measuring device of claim 6 wherein the executable instructions further comprise observing with the camera a mark on the first plane in a fourth 2D image, the mark not coinciding with a point of illumination by a distance meter, and determining fourth 3D coordinates of the mark based at least in part on the fourth 2D image.

8. The 3D measuring device of claim 6 wherein the executable instructions further comprise causing the camera to capture, in a fourth 2D image, a hole in the first plane and determining a diameter of the hole based at least in part on the fourth 2D image and on the equation of the first plane.

9. The 3D measuring device of claim 6 wherein the executable instructions further comprise:

causing the light source to send a fourth beam of light to a fourth object point on a second surface, the second surface being a planar surface perpendicular to the first plane;

causing the noncontact 3D measurement device to receive a fourth reflected light and determine a fourth distance to the fourth object point in response, the fourth reflected light being a portion of the fourth beam of light reflected by the fourth object point;

determining an angle of the fourth beam of light relative to the AACMM;

determining fourth 3D coordinates of the fourth object point based at least in part on the fourth distance and the fourth angle of the fourth beam of light relative to the AACMM;

causing the camera to obtain a fourth 2D image of the second surface, the fourth 2D image having a fourth spot of light caused by the fourth beam of light intersecting the second surface at the fourth object point;

causing the light source to send a fifth beam of light to a fifth object point on the second surface;

causing the noncontact 3D measurement device to receive a fifth reflected light and determine a fifth distance to the fifth object point in response, the fifth reflected light being a portion of the fifth beam of light reflected by the fifth object point;

determining an angle of the fifth beam of light relative to the AACMM;

determining fifth 3D coordinates of the fifth object point based at least in part on the fifth distance and the fifth angle of the fifth beam of light relative to the AACMM;

causing the camera to obtain a fifth 2D image of the second surface, the fifth 2D image having a fifth spot of light caused by the fifth beam of light intersecting the second surface at the fifth object point; and

determining when the first surface is a second plane shared by the fourth object point and the fifth object point, an equation for the second plane based at least in part on the fourth 3D coordinates, the fifth 3D coordinates, and the equation for the first plane.

10. The 3D measuring device of claim 9 wherein the executable instructions further comprise:

causing the light source to send a sixth beam of light to a sixth object point on a third surface, the third surface being a planar surface perpendicular to the first plane and the second plane;

causing the noncontact 3D measurement device to receive a sixth reflected light and determine a sixth distance to the sixth object point in response, the sixth reflected light being a portion of the sixth beam of light reflected by the sixth object point;

determining an angle of the sixth beam of light relative to the AACMM;

determining sixth 3D coordinates of the sixth object point based at least in part on the sixth distance and the sixth angle of the sixth beam of light relative to the AACMM;

causing the camera to obtain a sixth 2D image of the third surface, the sixth 2D image having a sixth spot of light caused by the sixth beam of light intersecting the third surface at the sixth object point; and

determining when the third surface is a third plane that includes the sixth object point, an equation for the third plane based at least in part on the sixth 3D coordinates, the equation of the first plane, and the equation of the second plane.

11. The 3D measuring device of claim 6 wherein the executable instructions further comprise determining a second dimension associated with a second feature of the first surface based at least in part on the equation of the first plane and on one of the first 2D image, the second 2D image, and the third 2D image.

12. The 3D measuring device of claim 11 wherein the executable instructions further comprise identifying the second feature based at least in part on the second dimension.

13. The 3D measuring device of claim 1 wherein the AACMM further includes at least one probe, the at least one probe selected from a group consisting of a tactile probe and a scanner.

14. The 3D measuring device of claim 13 wherein the executable instructions further comprise measuring a plurality of points on an inspection object with the at least one probe.

15. The 3D device of claim 14 wherein the executable instructions further include positioning the inspection object within an environment based at least in part on the plurality of measured points and on the first 3D coordinates of the first object point.

16. The 3D device of claim 1 wherein the executable instructions further include determining a superimposed 3D image based at least in part on 3D coordinates obtained from at least one of:

a tactile probe attached to the AACMM, a scanner attached to the AACMM, a computer-aided design (CAD) model, and a rendered 3D image.

17. The 3D device of claim 16 wherein the executable instructions further include determining a background 3D image based at least in part on a combination of 2D camera images of a background environment and corresponding 3D coordinates of points in the background environment, the corresponding 3D coordinates of points in the background environment determined based at least in part on readings of the 3D non-contact measurement device and readings of the at least one position transducer.

18. The 3D device of claim 17 wherein the 3D device further includes a user display device separate from the AACMM.

19. The 3D device of claim 18 wherein the executable instructions further include superimposing on the user display the superimposed 3D image over the background 3D image.

20. The 3D device of claim 19 wherein the 3D device further includes a user control and the executable instructions further include adjusting on the user display the superimposed 3D image relative to the background 3D image based at least in part on a signal from the user control.

21. The device of claim 16 wherein the 3D device further includes a user display that has a second camera, the second camera being provided with a position/orientation sensor that provides information about the position and orientation of the second camera, the second camera being configured to provide a second camera image.

22. The device of claim 21 wherein the position/orientation sensor includes a sensor selected from a group consisting of:

an accelerometer or inclinometer, a gyroscope, a magnetometer, an altimeter, a global positioning system (GPS), a local GPS system, and photogrammetry targets configured to work with one or more photogrammetry cameras.

23. The device of claim 21 wherein the executable instructions further include displaying on the user display a background representation based at least in part on the second camera, the executable instructions further including superimposing the superimposed 3D representation onto the background representation, the superimposed 3D representation based at least in part on the position and the orientation of the second camera.

24. The device of claim 21 wherein the executable instructions further including providing a background display based at least in part on 2D images from the second camera, wherein the 2D images are updated in response to changes in position and orientation of the second camera.