CA2350223A1 - System and method for automated non-contact parts inspection - Google Patents

System and method for automated non-contact parts inspection Download PDF

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Publication number
CA2350223A1
CA2350223A1 CA002350223A CA2350223A CA2350223A1 CA 2350223 A1 CA2350223 A1 CA 2350223A1 CA 002350223 A CA002350223 A CA 002350223A CA 2350223 A CA2350223 A CA 2350223A CA 2350223 A1 CA2350223 A1 CA 2350223A1
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Canada
Prior art keywords
inspection
surface image
inspection system
scanner
reference criteria
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002350223A
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French (fr)
Inventor
Alexander Gimelshtein
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AG AUTOMATION/CONTROLS Inc
Original Assignee
A.G. AUTOMATION/CONTROLS INC
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Filing date
Publication date
Application filed by A.G. AUTOMATION/CONTROLS INC filed Critical A.G. AUTOMATION/CONTROLS INC
Publication of CA2350223A1 publication Critical patent/CA2350223A1/en
Abandoned legal-status Critical Current

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Abstract

An automated non-contact parts inspection system includes a high resolution scanner to scan a part under inspection and generate digital linear images of surfaces of the part. A computer is coupled to the scanner and receives the surface images therefrom. The computer executes a part inspection routine and compares the surface images with reference criteria relating to the surface images that are stored in a database within computer memory to determine if the part under inspection meets desired standards.

Description

Sj'STEM A-ND METHOD FOR AUTOMAT .D NON-CONTACT
PARTS INSPECTION
Field of the Invention The present invention relates in general to the inspection of parts, and more specifically to a system and method for automated, non-contact parts inspection.
Background of the Invention In order to ensure that manufactured mechanical parts, components, etc. ("parts") meet required standards in terms of dimensions, tolerances and/or shapes, mechanical parts are typically inspected prior to delivery. Presently, two known inspection methods are used to inspect parts, namely contact and non-contact inspection methods.
During contact inspection, a part to be inspected is manually placed on a fixture by an inspector. Measurement instruments such as calipers, micrometers, gauges etc. .. are then used by the inspector to inspect the part and determine if the part meets standards. In some cases, analog, digital or go/no-go gauges and fixtures are also used. Once the part has been inspected, the part is removed from the fixture and is replaced with the next part to be inspected. As will be appreciated, since the measurements and the decision as to whether the part meets standards are performed by the human inspector, human error is a factor in the inspection process.
Also, the inspection process is slow.
During non-contact inspection, laser interferometers or vision systems are used to acquire images of the part under inspection. The acquired images are then processed to determine whether the part meets quality standards. Although these non-contact inspection systems speed up the inspection process, other problems exist. In particular, the laser interferometers and vision systems used in these non-contact inspection systems are non-linear and as a result, the images acquired by these inspection systems are distorted. This of course reduces the accuracy of the inspection process. In addition, these non-contact inspection systems are very expensive.
In the past when statistical inspection control was implemented by most manufacturers and only a sampling of manufactured parts were actually inspected, contact inspection was acceptable. However with manufacturers moving
-2-towards higher ISO standards, 100% inspection control is required. As a result, high speed inspection systems that exhibit high accuracy are required.
It is therefore an object of the present invention to provide a novel system and method for automated parts inspection.
Summary of the Invention According to one aspect of the present invention there is provided an automated non-contact parts inspection system comprising:
an automated non-contact parts inspection system comprising:
a scanner to scan a part under inspection and generate a digital linear image of a surface of said part; and a processor coupled to said scanner and receiving the surface image therefrom, said processor executing a part inspection routine and comparing the surface image with reference criteria relating to said surface image that is stored in memory to determine if said part under inspection meets desired standards.
In a preferred embodiment, the part inspection routine generates a record of the comparison between the surface image and the reference criteria.
The record includes the surface image and information concerning differences between the surface image and the reference criteria. The surface image can be stored in a CAD
file format or converted into another desired file format. The part inspection routine permits the surface image to be displayed and/or manipulated.
Preferably, the computer presents a visual indication as to whether the part meets or fails the desired standards. The reference criteria may relate to one or more of part dimensions, part tolerances and part shape.
The inspection system may further include a part moving mechanism to place the part on the scanner and to remove the part from the scanner.
According to another aspect of the present invention there is provided an automated non-contact parts inspection system comprising:
a high resolution scanner to scan a part under inspection and generate linear digital images of surfaces of said part; and a computer coupled to said scanner and receiving the surface images therefrom, said computer executing a part inspection routine and comparing the
-3-surface images with reference criteria relating to said surface images that are stored in a database within computer memory to determine if said part under inspection meets desired standards.
According to still yet another aspect of the present invention there is provided a method for automated, non-contact inspection of parts comprising the steps of:
scanning a surface of a part under inspection and generating a digital linear image of said surface;
comparing said surface image with reference criteria relating to said surface image to determine differences between said surface image and said reference criteria; and generating output indicating whether the part meets desired criteria based on the results of said comparison.
The present invention provides advantages in that since the inspection process is automated, human error during inspection is avoided. Also, automation of the inspection process system allows a human inspector to perform other duties whiles inspections are being performed. In addition, the present invention provides advantages in that the inspection system is relatively inexpensive as compared to prior art inspection systems. Furthermore, since a high resolution scanner is used to acquire linear images of parts under inspection, a high resolution can be achieved.
Brief Desc~;Cition of the Detailed Drawinu~c Embodiments of the present invention will now be described more fully with reference to the accompanying drawings in which:
Figure 1 is a schematic diagram of a non-contact part inspection system in accordance with the present invention;
Figure 2 is a flow chart outlining the steps performed during non-contact inspection of parts using the inspection system of Figure 1; and Figure 3 is a schematic diagram of another embodiment of a non-contact part inspection system in accordance with the present invention.
-4-Turning now to Figure l, a non-contact part inspection system in accordance with the present invention is shown and is generally indicated to by reference numeral 10. As can be seen, inspection system 10 includes a high-s resolution digital flat bed scanner 12 to scan a surface 14a of a part 14 under inspection and generate a digital linear image of the scanned part surface.
Within the context of this application, linear refers to the fact that the dimensions or geometry of the scanned surface are not distorted in the part surface image. The resolution of the scanner 12 can be selected to suit the particular requirements of the inspection process. For example, if a scanner having a 1200 DPI is used, images having a resolution in the order of about 0.001" (0.025 mm) can be acquired. In this embodiment, scanner 12 includes a reflective light source 12a located beneath a glass surface 12b onto which the part 14 being inspected is placed. A cover 12c is disposed over the glass surface 12b to inhibit dust and other contaminants from settling on the glass surface 12b and to inhibit extraneous light from degrading the quality of scanned images. Scanner 12 is connected to a personal computer 16 via a serial data cable 18. Computer 16 executes a part inspection routine 20 that accesses a database storing reference criteria associated with part surfaces. In the present embodiment, the reference criteria relates to part dimensions, tolerances and/or shape.
During execution of the part inspection routine 20, images of scanned parts are compared with corresponding reference criteria to determine if the scanned parts meet standards.
A pick-and-place unit 22 is associated with the scanner 12 and is operable to place parts on the glass surface 12b of the scanner and remove parts from the glass surface of the scanner 12. In this manner, the entire part inspection process can be automated.
Initially, reference criteria associated with the parts to be inspected is established and digitized and is then stored in the database in CAD file format or other suitable file format. The reference criteria establish benchmarks for parts in terms of desired standards. Thresholds with respect to part dimensions, tolerances and shape are then defined for the reference criteria. The thresholds establish acceptable deviations from the reference criteria. In this manner, parts can be analyzed in terms of shape, dimensions, tolerances and/or other visual features. With
-5-the reference criteria and thresholds established, the inspection system 10 is ready for operation.
During operation, an operator using the computer 16 enters the type of part being inspected. The part inspection routine 20 in turn accesses the database and retrieves the appropriate reference criteria and thresholds associated with the parts.
Once this has been done, the pick-and-place, unit 22 is conditioned to place a part 14 to be inspected in the scanner 12 with the surface 14a of the part to be scanned resting on the glass surface 14b. The cover 14c of the scanner 12 is then closed and a digital linear image of the part surface is generated (see step 30 in Figure 2). Once the part surface image has been generated, the part surface image is conveyed to the computer 16 and is stored in memory.
During execution of the part inspection routine 20, when the computer 16 receives the part surface image from the scanner 12, the computer 16 compares the part surface image with the reference criteria and thresholds to determine if the part 1 S surface image deviates from the reference criteria by more than the thresholds and hence, determine if the part surface meets standards (step 32). The results of the comparison are then displayed on the monitor 16a of the computer (step 34).
If the results of the inspection indicate that the part surface does not meet standards, the part inspection routine 20 creates a record in a failed parts database and signals the pick-and-place unit 22 to remove the part from the scanner 12 and place it in a failed parts bin. If the results of the inspection indicate that the part surface meets standards, the part inspection routine 20 creates a record in a passed parts database and either signals the pick-and-place unit 22 to re-orient the part 14 on the glass surface 12b of the scanner 12 so that another of its surfaces can be inspected or to remove the part from the scanner 12 and place the part in a passed parts bin.
With respect to failed parts, each record in the failed parts database includes the part surface image as well as a detailed comparison of the part surface image and the reference criteria. This enables the specific reasons for parts failing to meet standards to be determined so that appropriate changes in the part manufacturing process can be made to reduce the number of defective parts that are produced.
-6-With respect to passed parts, each record in the passed parts database includes the part surface image as well as a detailed comparison of the part surface image and the reference criteria so that slight variations between the reference image and the part surface image that are within the thresholds can be determined.
Updates to the reference criteria and the thresholds and/or the part manufacturing process can be made depending on differences between the comparison.
The part inspection routine 20 also allows the part surface images stored in the failed and passed parts databases to be examined visually, manipulated and/or converted into other desired file formats (step 36).
As will be appreciated, the inspection system 10 automates the pass or fail decision making process avoiding the problems associated with human inspection.
Since the pass or fail decision is automated, the decision making process can be carried out at very high speeds. For example, a part having a part surface to be inspected with an area equal to about 10 in 2 can be scanned and a pass or fail decision made in approximately one to three seconds depending on the processor speed of the computer 16. This represents a significant increase in speed over prior art inspection systems.
As will also be appreciated, depending on the degree of quality control required, the reference criteria and thresholds can be adjusted. In this manner, the comparison can be limited to selected dimensions, tolerances and/or shape of the parts.
When the inspection system 10 includes the pick-and-place unit 22, the entire inspection process can be performed in a "lights-out" environment.
However, as will be appreciated, the pick-and-place unit 22 can be replaced with other types of robotic equipment to move parts automatically or can be omitted from the inspection system 10. In the latter case, the placement of parts on the glass surface 12b of scanner 12 and the removal of parts from the scanner is performed manually by an operator. In this case, the results of the comparison that are displayed on the computer monitor 16a are used by the operator to determine where inspected parts are placed.
Although the inspection system 10 of Figure 1 includes a flat bed scanner 12 with a reflective light source 12a, other scanners can be used as shown in Figure 3. In this embodiment, the scanner 112 includes a through-beam light source 112a positioned above the glass surface 112b. Scanners of this nature have been found to be more suitable to inspect contoured (i.e. non-flat) parts. Also, although the inspection system is described as including a personal computer executing the part inspection routine, other processors can be used to compare the part surface image and reference criteria and determine whether parts meet the threshold criteria.
As mentioned previously, depending on the accuracy of the inspection system that is required, the resolution of the scanner 12 can be varied. As will be appreciated, a reduction in the resolution of the scanner 12 increases the speed of the parts inspection process.
In addition to the computer 16 presenting a visual indication of the comparison results, the computer can provide output to an audio or other feedback device that provides appropriate feedback to the operator to inform the operator of the comparison results.
The present invention provides advantages in that parts can be inspected accurately and quickly. The parts may be of any complexity, made from virtually any material and manufactured by various fabrication technologies.
Such technologies include machining, stamping, laser based, plasma based, EDM
based, water jet-cutting, die casting or manual based.
As will be appreciated by those of skill in the art, although preferred embodiments of the present invention have been described and illustrated in detail, various changes and modification may be made without departing from the spirit and scope thereof as defined by the appended claims.

Claims (20)

What is Claimed is:
1. An automated non-contact parts inspection system comprising:
a scanner to scan a part under inspection and generate a digital linear image of a surface of said part; and a processor coupled to said scanner and receiving the surface image therefrom, said processor executing a part inspection routine and comparing the surface image with reference criteria relating to said surface image that is stored in memory to determine if said part under inspection meets desired standards.
2. An inspection system as defined in claim 1 wherein said part inspection routine generates a record of the comparison between said surface image and said reference criteria.
3. An inspection system as defined in claim 2 wherein said record includes said surface image and information concerning differences between the surface image and said reference criteria.
4. An inspection system as defined in claim 3 wherein said surface image is stored in a CAD file format.
5. An inspection system as defined in claim 3 wherein said part inspection routine permits the surface image to be displayed and/or manipulated.
6. An inspection system as defined in claim 4 wherein said part inspection routine permits the surface image to be converted into a desired file format.
7. An inspection system as defined in claim 2 wherein said memory stores a database of reference criteria relating to surfaces of a variety of parts to be inspected.
8. An inspection system as defined in claim 2 wherein said computer presents a visual indication as to whether the part meets or fails said desired standards.
9. An inspection system as defined in claim 1 wherein said reference criteria relates to one or more of part dimensions, part tolerances and part shape.
10. An inspection system is defined in claim 9 wherein said reference criteria further includes thresholds defining acceptable deviations of said surface image from said reference criteria.
11. An inspection system as defined in claim 1 wherein said scanner is a high-resolution flat bed scanner.
12. An inspection system as defined in claim 1 further comprising a part moving mechanism to place the part on said scanner and to remove the part from said scanner.
13. An inspection system as defined in claim 12 wherein said part-moving mechanism is a pick-and-place unit.
14. An automated non-contact parts inspection system comprising:
a high resolution scanner to scan a part under inspection and generate linear digital images of surfaces of said part; and a computer coupled to said scanner and receiving the surface images therefrom, said computer executing a part inspection routine and comparing the surface images with reference criteria relating to said surface images that are stored in a database within computer memory to determine if said part under inspection meets desired standards.
15. An inspection system as defined in claim 14 wherein said part inspection routine generates records of the comparisons between said surface images and said reference criteria, each of said records including a surface image and information concerning differences between the surface image and the corresponding reference criteria.
16. An inspection system as defined in claim 15 wherein said part inspection routine permits the surface images in said records to be displayed, manipulated and/or converted to a desired file format.
17. An inspection system as defined in claim 14 wherein said reference criteria further includes thresholds defining acceptable deviations of said surface image from said reference criteria.
18. A method for automated, non-contact inspection of parts comprising the steps of:
scanning a surface of a part under inspection and generating a digital linear image of said surface;
comparing said surface image with reference criteria relating to said surface image to determine differences between said surface image and said reference criteria; and generating output indicating whether the part meets desired criteria based on the results of said comparison.
19. The method of claim 18 further comprising the step of creating a record of the results of said comparison, said record including said surface image and information concerning differences between the surface image and said reference criteria.
20. The method of claim 19 further comprising the step of automatically placing the part on a scanner prior to said scanning step and automatically removing the part from said scanner after said scanning step.
CA002350223A 2000-06-15 2001-06-12 System and method for automated non-contact parts inspection Abandoned CA2350223A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US61264700A 2000-06-15 2000-06-15
US09/612,647 2000-06-15

Publications (1)

Publication Number Publication Date
CA2350223A1 true CA2350223A1 (en) 2001-12-15

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA002350223A Abandoned CA2350223A1 (en) 2000-06-15 2001-06-12 System and method for automated non-contact parts inspection

Country Status (1)

Country Link
CA (1) CA2350223A1 (en)

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