WO2009042903A1

WO2009042903A1 - Method and apparatus for measuring transmitted optical distortion in glass sheets

Info

Publication number: WO2009042903A1
Application number: PCT/US2008/077930
Authority: WO
Inventors: Donivan M. Shetterly; Jason C. Addington; Michael J. Vild
Original assignee: Glasstech, Inc.
Priority date: 2007-09-28
Filing date: 2008-09-26
Publication date: 2009-04-02

Abstract

An apparatus and associated method for measuring transmitted optical distortion in a glass sheet, including a glass stand which receives a glass sheet for mounting between a background screen which includes a matrix of spaced apart dots, and a digital camera which captures an image of the dot matrix transmitted through the glass sheet. The digital image is downloaded to a computer that is suitably programmed to analyze the image data to determine the magnification and lens power indicative of optical distortion in the observed image of the dot matrix transmitted through the glass sheet. The magnification and lens power is determined for each dot of interest in the dot array by comparing (1) the distances between the dot of interest and its neighboring dots with (2) the known, undistorted distances between those dots.

Description

METHOD AND APPARATUS FOR MEASURING TRANSMITTED OPTICAL DISTORTION IN GLASS SHEETS

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application number 60/995,827 filed 28 September 2007, which application is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method and apparatus for measuring transmitted optical distortion in glass sheets.

2. Background Art

Manufacturers of glass sheets, particularly glass sheets formed into various curved shapes for use as automotive windshields and backlites, are interested in measuring and evaluating the amount of optical distortion in the formed sheets that might be perceived by a human observer, such as the operator or passenger in a vehicle in which the glass may be mounted as the windshield or backlite.

SUMMARY OF THE INVENTION

The present invention provides an apparatus and associated method for measuring transmitted optical distortion in a glass sheet, including a glass stand which receives a glass sheet for mounting between a background screen which includes a matrix of spaced apart dots, and a digital camera which captures an image of the dot matrix transmitted through the glass sheet. The digital image is downloaded to a computer that is suitably programmed to analyze the image data to determine the magnification and lens power indicative of optical distortion in the observed image of the dot matrix transmitted through the glass sheet. The magnification and lens power is determined for each dot of interest in the dot array by comparing (1) the distances between the dot of interest and its neighboring dots with (2) the known, undistorted distances between those dots.

Various statistical information can be reported for predefined areas of the glass sheet, including the maximum, minimum, range, mean, and standard deviation in lens power, or other indices of distortion which may be of interest.

The system and method of the present invention can take the form of a stand-alone laboratory or production floor installation, or it may be installed inline of other processing stations utilized in glass sheet processing equipment, such as automobile windshield and backlite fabrication lines.

The system may be programmed by the user to graphically and numerically display various indicia of optical distortion, including those indicia most relevant to industry standards such as ECE R43, or other indicia considered relevant in the industry to the analysis of the optical transmission quality of formed and fabricated glass sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a perspective view of the apparatus of the present invention;

FIGURE 2 is a front view of the dot array sheet used in one embodiment of the present invention;

FIGURE 3 is a computer display screen view of the measured results for a glass windshield measured using the apparatus and method of the present invention;

FIGURE 4 is a computer display screen shot illustrating a depiction of vertical distortion measured in a glass windshield; FIGURE 5 is a schematic diagram of the system of the present invention installed in-line in a typical automotive backlite forming and tempering line;

FIGURE 6 is a schematic diagram of the system of the present invention installed in-line in a typical automotive windshield forming line;

FIGURE 7 is a perspective view of the apparatus of the present invention installed in-line in a typical glass sheet forming line; and

FIGURE 8 is a flow chart of one of the process operations performed as part of the image analysis in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to Figure 1, the system 10 of the present invention includes a glass stand 12 for mounting a glass sheet 14 between a point array screen 16 and a digital camera 18. The digital camera 18 is operatively connected to a conventional computer 20 to facilitate periodic downloading of image data for processing and analysis according to the method of the present invention. In one embodiment, the glass stand includes first and second adjustment mechanisms 22 and 24 to allow for rotational adjustment of the mounting frame 26 about a generally horizontal axis, and third adjustment mechanism 28 to rotate the glass frame 26 about a generally vertical axis, in order to orient the glass sheet in the same position in which the glass would be installed in use in a vehicle. The dot array screen provides an array of dots positioned in a selected pattern and at a known predetermined distance from each other such that the image of the dot array is projected onto the camera 18 through the glass sheet 14 mounted therebetween.

In one embodiment of the invention, as illustrated in Figure 2, the dots on the screen 16 are arranged such that each dot (dot of interest, C) other than boundary dots has six immediate neighboring dots, N1-N6, that are at an equal distance from the dot of interest in a hexagonal pattern. In one embodiment of the invention, the dots on the array screen are circles 3.5 millimeters in diameter, and the distance between the center of each dot and each of its six immediate neighbors is 5.5 millimeters. In another embodiment of the invention, the dots on the array screen are circles are 4 millimeters in diameter, and the distance between the center of each dot and each of its six immediate neighbors is 6.25 millimeters. It will be appreciated, however that the "undistorted" dot sizes and distances utilized in the analysis are not the actual sizes and distances measured on the screen 16, but instead are the dot size and distance measured in an image focused at the distance between the camera and the mounting location of the glass sheet. It will also be appreciated that, though the dot is preferably circular in shape, other similar shapes may be employed without departing from the spirit of the present invention.

The digital camera 18 is mounted to collect images of the dot array screen 16 transmitted through the glass sheet 14 mounted on the glass stand. In one embodiment, the digital camera is a commercially available 12.8 MPa SLR- type camera. In another embodiment of the invention, a 16 MPa, 3 frame-per-second GE4900 model CCD camera, available from Prosilica, Inc. of Burnaby, British Columbia, Canada, is employed as the camera.

The camera 18 is connected via a conventional data line to a computer 20 which is suitably programmed to acquire the digital image from the camera, process the image data to obtain the desired resolution for the data, and analyze the data to develop various indicia of distortion in the glass sheet according to the method of the present invention as further described herein. The computer is also programmed to present the derived image distortion information in both graphical (e.g., color-coded images) and statistical forms.

In one embodiment, the dot array screen is a light box that utilizes conventional lighting (such as fluorescent lights) behind a translucent panel upon which a contrasting dot array, preferably in the form of black dots, is printed, painted, or otherwise applied using conventional methods. The digital camera is connected to the computer using known methods, preferably so that the acquisition of the image by the camera may be controlled by the computer. The computer 20 is programmed to perform the image acquisition, modification and analysis steps described hereinafter for each glass sheet to be measured, as well as to display the resulting distortion indicia in graphical and/or numeral formats.

In one embodiment, the system calculates and displays lens power data associated with various predefined zones on the glass sheet. In particular, ECE R43 specifies various zones of interest on automotive windshields and backlites for which distortion data thresholds are measured and analyzed. In the table shown in Figure 3, for example, various lens power data is provided in millidiopters for each zone, including the maximum lens power (positive magnification), minimum lens power (negative magnification), range (the difference between the identified maximum and minimum lens powers), mean lens power, and standard deviation. While ECE R43 zones are defined, the user may also define other zones of interest as desired.

One embodiment of the present invention also provides a graphical, color-coded display of the distortion using the measurement data developed for the displayed glass sheet. For example, as illustrated in Figure 3, all areas having positive lens power are shown in red, those areas having a negative lens power are shown in green, and those areas having zero lens power (no distortion) are shown in black.

According to the method of the present invention, the digital image data acquired from the camera 18 is resolved, or filtered, to eliminate noise, reduce resolution of the image to that approximating how the image would be perceived by a human viewer, and/or otherwise reduce the amount of image data as desired to eliminate unnecessary processing time. Various known filtering techniques, such as data averaging, may be employed to resolve the data. In one embodiment, two standard filters are developed to provide data which has been empirically shown to correlate with the "4-5-6" and "4-5-12" filters used on another optical distortion measuring system currently available from ISRA Surface Vision GmbH, so as to allow industry users to develop comparable distortion indicia for their products regardless of which measuring system is used.

The principal image distortion analysis process is charted in Figure 8. The resolved image data is then processed to locate the center of each of the dots in the image (at 80). Once the centers are located, a magnification value is developed for each dot in the image. In one embodiment, the distance from the dot of interest (the center dot) from each of its six neighbors is calculated (shown at 82). The ratio of each of those distances over the known, undistorted distance is established. These ratios represent six directional magnification vectors for that dot. In one embodiment, a coordinate transformation is then conducted using the directional magnification vectors to express the magnification in horizontal and vertical vector components. The lens power is then calculated for each dot (shown at 84). This value is typically expressed in millidiopters, the quantity often used in the glass industry for this measurement. The system proceeds in a stepwise fashion to determine magnification and lens power values for each of the dots in the image (shown at 86). The lens power is then also preferably resolved into its vertical, horizontal, and shear components.

Various statistical data is next developed for predefined regions and predefined zones in the glass sheet. Figure 3 illustrates a region 36 utilized in one embodiment of the invention. The size and shape of the region 36 may be defined by the user depending upon the desired precision and amount of derived information, and/or processing constraints. In one embodiment, a region size of 40 millimeters by 80 millimeters is used. The region is moved in a stepwise fashion through the zone so that each point in the zone is included in at least one of the region processing steps. At each step, each point in the region is accessed to determine the maximum lens power and the minimum lens power for all the points in the region, as well as the range (the difference between the maximum lens power and the minimum lens power) for those points. At the next step, the region is moved within the zone to include one or more new points and the maximum, minimum and range are determined for all the points in the region at its new location. This process is repeated until all the points in the zone have been included in the region for at least one step of the regional processing steps. It will be appreciated that the region can be repositioned within the zone at each step by any distance, as desired by the user, so long as all the points within the zone are located within the region during at least one of the processing steps. In one embodiment, the region is moved through the zone one pixel at a time, so that each point in the zone is, for example, the topmost, leftmost point in the region at a particular processing step. Of course, processing time can be reduced by moving the region so as few points as possible are included in the region in more than one processing step. For example, if the region was suitably sized and shaped to include one quarter of the dots within a zone at each step, minimal processing time could be achieved by moving the region to a position in which it contains no dots processed in the previous step (i.e., moving the region to each of the four locations including one quarter of the dots within the zone) so that each dot is included in only one regional processing step.

In the embodiment illustrated in Figure 3, once processing has been completed for a particular zone, the relevant distortion indicia, and the location of the region within the zone, are displayed for that region which has the greatest range (i.e. , the greatest difference between its maximum lens power and its minimum lens power). Thus, when a particular glass sheet is completely processed utilizing the method illustrated in Figure 3, a single region will be identified in each of the zones of the glass sheet, with the identified regions representing the location and value of the maximum lens power range for that zone. It will be appreciated that other optical distortion indicia can be calculated, identified, and displayed by region and/or for each zone, as desired by the user.

Referring again to Figure 3, various distortion indicia are developed for predefined zones 30-34. In one embodiment of the system, the image distortion value associated with each point is the lens power in millidiopters, and the distortion indicia includes the maximum lens power, the minimum lens power, the range (i.e., maximum minus minimum lens power) the mean, and the standard deviation for each ECE R43 zone on the glass sheet thereby providing the analysis and data used to measure the optical quality of glass according to current defacto international standards. Of course, it will be appreciated that other distortion and indicia may be developed using the techniques of the present invention. Similarly, other zones of interest may be defined on the glass sheet as desired, depending upon industry standards, design concerns, and/or the nature of the use of the glass sheet.

As illustrated in Figures 3 and 4, data and graphical displays relating only to horizontal distortion, or only to vertical distortion, can be similarly provided for each glass sheet. It should be noted that the distortion often characterized by those in the art as "horizontal" distortion, illustrated in Figure 3, is actually distortion indicia relating to the vertical component of the variation in the distances between the dots and the distorted image and an undistorted image. Similarly, the distortion often characterized by those skilled in the art as vertical (or drawline) distortion, illustrated in Figure 4, actually depicts the horizontal component of the variance in the distance between the dots from the distorted image (viewed through the glass sheet) and an undistorted image of the dot array screen.

In the embodiment of the invention shown in Figure 2, the system 10 is provided as a stand-alone product which may be located in an engineering laboratory or production environment. Other contemplated embodiments of the system 10 include in-line installations in glass sheet processing systems, whereby the optical distortion may be measured for each glass sheet as it is conveyed through the fabrication process.

For example, Figure 5 illustrates a typical automotive backlite heating, bending, and tempering system 50 which includes the system 10 of the present invention in-line. In this installation, the glass sheets (indicated as G) enter a heating zone 52 where the glass is softened to a temperature suitable for forming the glass into the desired shape. The heated glass sheet is then conveyed to a bending station 54 where the softened sheet is formed to the desired shape, and thereafter further conveyed to a cooling station 56 where the glass sheet is cooled in a controlled manner to achieve the appropriate physical characteristics. In this embodiment, the glass sheet would then be conveyed out of the cooling station to a transport position from which the sheet is moved from the conveyor and mounted on the glass stand for image acquisition and analysis according to the present invention. Following the measurement, the glass sheet would then be removed from the stand and deposited on a conveyor, or in a storage rack, for further processing. It will be appreciated that the transport and conveyance of the glass can be achieved by using known techniques such as by roller, air-float, or belt conveyors, positioners, and robotic arms, in order to handle the glass in the manner described.

Figure 6 similarly schematically illustrates an in-line installation of the system 10 of the present invention in a typical windshield fabrication system, which may include a heating station 62, a bending station 64, a cooling station 66, and a lamination station 68, upstream of the measuring system 10. It will be appreciated that the measuring system 10 of the present invention could alternatively be mounted in-line at various other points in glass sheet fabrication systems as desired to maximize the production rate of the system, so long as the optical distortion measurements are taken after the glass sheet has been formed to its final shape.

Figure 7 is a graphic illustration of the system 10 integrated in-line on the conveyor at the exit of a glass sheet bending system, such as those described in Figures 5 and 6. Glass is typically conveyed from the cooling section of a bending and tempering/annealing system by use of a belt or roller conveyor, shown in Figure 7 as conveyor 70, for various secondary processing operations, such as post-forming and soldering for heater grid and other electrical connections, as well as for other inspection operations, such as shape analysis. The system 10 of the present invention may be integrated in-line by arranging the camera 18 and the background array 16 such that, each glass sheet 14 may be picked up by a robotic arm 72 when it reaches a pre-defined position on the conveyor and oriented in the path between the camera 18 and the screen 16 at the desired tilt angle. The image of the array is then acquired and analyzed as previous described to determine magnification, lens power, and other desired statistical information.

After the image of the glass sheet is acquired, the robotic arm 72 is controlled to re-position the glass sheet on the conveyor, and the process is repeated for other selected glass sheets as they move along the conveyor from the exit of the heating, bending and cooling system to one or more post processing stations as described above.

As shown in Figure 7, positioning stops 74,76, 78 may be located to accurately position the glass sheet as it moves on the conveyor into position for retrieval by the robot arm. It will be appreciated by those skilled in the art that various known positioning apparatus may be employed for this purpose. Similarly, although the camera and array screen are arranged in the illustrated embodiment such that the path between the camera 18 and background array 16 is parallel to the direction of conveyance of the glass, various alternative arrangements of the system

10 along the conveyor 70 may be employed without departing from the spirit of the invention.

In one embodiment of the system, the user can mask particular zones and/or irrelevant anomalies, so as to eliminate data from those areas from processing or further consideration. For example, detection and masking of the edge of the glass sheet, paint bands, heater grid patterns, and antenna wires, and/or other attachments or fixtures can be accomplished as desired to eliminate these areas from review and consideration.

In one embodiment the distortion indicia is formatted and stored in

Microsoft Excel^® format for ease of further review and manipulation by the user.

While embodiments of the present invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. An apparatus for measuring optical distortion in a glass sheet including: a digital camera, a background screen including a matrix of spaced apart dots positioned on a contrasting background, a glass stand for receiving and maintaining the glass sheet in the path between the camera and the background screen so that the camera captures an image of the matrix transmitted through the glass sheet, and a computer including logic for receiving the captured image data and determining a magnification and lens power associated with each point of interest on the matrix based upon a comparison of (1) the distances between the dot of interest and one or more neighboring dots in the captured image, and (2) the known, undistorted distances between those dots.

2. An apparatus for measuring optical distortion in a glass sheet including: a digital camera, a background screen including a matrix of spaced apart dots positioned on a contrasting background such that all but the bordering dots are centered between six neighboring dots wherein each of the neighboring dots is equidistant from the center dot, a glass stand for receiving and maintaining the glass sheet in the path between the camera and the background screen so that the camera captures an image of the matrix transmitted through the glass sheet, and a computer including logic for receiving the captured image data and determining indicia of distortion associated with each point of interest on the matrix based upon a comparison of (1) the distances between the dot of interest and its six neighboring dots in the captured image, and (2) the known, undistorted distance between the center and each of its six neighboring dots.

3. In a system for fabricating glass sheets including a heating station for heating the glass sheet to a temperature adequate to soften the glass for forming into a desired shape, a bending station wherein the softened sheet is formed to the desired shape, a cooling station wherein the formed glass sheet is cooled in a controlled manner, and one or more conveyors for conveying the glass sheet from station to station during processing, an apparatus for measuring optical distortion in the glass sheet including: a digital camera; a background screen including a matrix of spaced apart dots positioned on a contrasting background, a glass stand for receiving and maintaining the glass sheet in the path between the camera and the background screen so that the camera captures an image of the matrix transmitted through the glass sheet; and a computer including logic for receiving the captured image data and determining indicia of distortion associated with each point of interest on the matrix based upon a comparison of the location of one or more of the dots in the captured image with a known, undistorted location for those dots.

4. A method for measuring optical distortion in a glass sheet including: capturing a digital image of a background screen including a matrix of spaced apart dots positioned on a contrasting background by aiming a camera at the background screen with the glass sheet position in the light path between the camera and the background screen so that the image is transmitted through the glass sheet, receiving the captured image data and determining a magnification and lens power associated with each point of interest on the matrix based upon a comparison of (1) the distances between the dot of interest and one or more neighboring dots in the captured image, and (2) the known, undistorted distances between those dots.

5. A method for measuring optical distortion in a glass sheet including: capturing a digital image of a matrix of spaced apart dots positioned on a contrasting background such that all but the bordering dots are centered between six neighboring dots wherein each of the neighboring dots is equidistant from the center dot, by aiming a camera at the background screen with the glass sheet position in the light path between the camera and the background screen so that the image of the matrix is transmitted through the glass sheet, receiving the captured image data and determining indicia of distortion associated with each point of interest on the matrix based upon a comparison of (1) the distances between the dot of interest and its six neighboring dots in the captured image, and (2) the known, undistorted distance between the center and each of its six neighboring dots.

6. A method for fabricating a glass sheet including: heating the glass sheet to a temperature adequate to soften the glass for forming to a desired shape; forming the glass sheet to the desired shape; cooling the glass sheet in a controlled manner to achieve the desired shape and physical characteristics in the glass sheet; and measuring the optical distortion in the formed glass sheet by capturing a digital image of a background screen including a matrix of spaced apart dots positioned on a contrasting background by aiming a camera at the background screen with the glass sheet positioned between the camera and the background screen so that the image is transmitted through the glass sheet and determining indicia of distortion associated with one or more points of interest on the matrix based upon a comparison of the position of the one or more points of interest in the captured image with the known, undistorted positions of those points.