Image analysis – Applications – Manufacturing or product inspection
Reexamination Certificate
1997-04-01
2001-05-01
Mehta, Bhavesh (Department: 2721)
Image analysis
Applications
Manufacturing or product inspection
C382S141000, C348S090000
Reexamination Certificate
active
06226395
ABSTRACT:
TECHNICAL FIELD
This invention relates to robotic welding systems and, more particularly, discloses a method and an apparatus for determining the configuration of a workpiece so that a robot welder will have the proper coordinates for the welding operation.
BACKGROUND OF THE INVENTION
Robotic, or automatic, welders accurately perform welding operations which would be difficult and/or time consuming if performed by a human. Human welders can visually perceive the area of the welding operation, the location of the elements to be welded, and compensate for the misalignment of the elements. However, robotic welders do not have such intelligence and need information about the workpiece, such as the coordinates of the elements to be welded, any elements which must be worked around, etc. This information is generally provided by a human, at least to some degree. For example, a human operator may, using manual controls, move the robotic welder sensing arm about the workpiece and instruct the robotic welder to store the coordinates of the bottom plate, an intersection of elements, a corner, etc. Also, the robotic welder can accept information about the ideal element locations from a computer assisted design (CAD) program which was used to draw the plans for the workpiece to be welded.
Elements may not be always placed in their “ideal” locations, they may be offset or skewed In many cases, this offset or skew does not affect the structural-integrity of the finished product as long as the offset or skew is within certain, usually generous, tolerances.
A robotic welder, especially one which has a “touch-sense” feature, can compensate for some offset or skew. However, if the offset or skew exceeds a certain amount then the robotic welder may start outside a compartment, rather than within it, and thereby perform the wrong welding operation.
Therefore, there is a need for a method which accurately determines the locations of the elements, as placed, so that the configuration of the workpiece will be accurately known by the robotic welder.
SUMMARY OF THE INVENTION
The present invention provides a method whereby the workpiece is automatically scanned to determine the precise location of the various elements. This information is then provided to the robotic welder so that the robotic welder will have exact information concerning the configuration of the workpiece and can flawlessly perform the programmed welding operation, even if the elements are not in the locations specified by the drawings for the workpiece.
The method of the present invention includes the steps of automatically scanning the workpiece from a plurality of locations to generate a three-dimensional picture of the workpiece, and then using this three-dimensional picture of the workpiece to obtain exact information regarding the location and orientation of each of the elements.
By scanning the workpiece from a plurality of locations (observation points) the present invention eliminates shadowing and other problems that may occur when one element conceals another element when viewed from a single observation point. Thus, even though a larger element may completely conceal a smaller element when the workpiece is viewed from a first observation point, the smaller element will be detected and its coordinates and other information obtained when the workpiece is viewed from a second observation point.
The present invention provides a method for determining the configuration of an object. The method includes the steps of setting a first position, scanning the object from the first position to a second position to obtain data on the object, setting a next position, scanning the object from the next position to a subsequent position to obtain additional data on the object, repeating the steps of setting the next position and scanning from the next position to the subsequent position to obtain additional data on the object until the desired portion of the object has been scanned, and processing the data to determine the configuration of the object. The configuration is then provided to a subsequent process.
Another method for determining the configuration of an object includes the steps of scanning the object in a first manner to obtain data on the object, scanning the object in a second manner to obtain additional data on the object, and processing the data to determine the configuration of the object. The configuration is then provided to a subsequent process.
Another method for determining the configuration of an object includes the steps of scanning the object in a linear manner to obtain data on the object, identifying areas of the object for which additional data is needed, scanning the areas to obtain the additional data, and processing the data and the additional data to determine the configuration of the object. The configuration is then provided to a subsequent process.
The present invention also provides an apparatus for determining the configuration of an object. The apparatus has scanning means for scanning the object to obtain data on the object, first means for moving the scanning means along a first path, second means for moving the scanning means along a second path, and a control means. The control means for controls the operation of the scanning means, the first means, and the second means, receives the data from the scanning means, and processes the data to determine the configuration of the object. The control means then provides the configuration to another apparatus for use in a subsequent operation, such as a welding operation, or uses the configuration to perform a subsequent operation.
Another apparatus has scanning means for scanning the object to obtain data on the object, first means for moving the scanning means along a first path, second means for moving the scanning means along a second path, and a control means. The control means controls the operation of the scanning means, the first means, and the second means, receives the data from the scanning means, processes the data to determine areas of the object for which additional data is needed, controls the operation of the scanning means, the first means, and the second means to obtain the additional data, and processes the data and the additional data to determine the configuration of the object. The control means then provides the configuration to another apparatus for use in a subsequent operation, such as a welding operation, or uses the configuration to perform a subsequent operation.
Another apparatus includes scanning means for scanning the object to obtain data on the object, first means for moving the scanning means along a first linear path, second means for moving the scanning means along a second linear path orthogonal to the first linear path, and a control means. The control means controls the operation of the scanning means, the first means, and the second means, receives the data from the scanning means, and processes the data to determine the configuration of the object. The control means then provides the configuration to another apparatus for use in a subsequent operation, such as a welding operation, or uses the configuration to perform a subsequent operation.
The present invention also provides a method for determining the configuration of an object. The method includes the steps of scanning the object to obtain a set of data points for the object, inspecting the set of data points to define a first plane and a second plane, determining an intersection line for the first plane and the second plane, and specifying the intersection line by a starting point and an ending point. The first plane comprises a first plurality of the data points and the second plane comprises a second plurality of the data points. The first plurality and the second plurality are smaller than the set and are part of the set.
Another method for determining the configuration of an object includes the steps of scanning the object to obtain a set of data points for the object, inspecting the set of data points to define a first plane and a second plane, determining
Mehta Bhavesh
Troutman Sanders LLP
Warner Charles L.
LandOfFree
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