Self-calibrating inspection system and method for inspecting items using it

Abstract

A self-calibrating inspection system and a corresponding article inspection method are provided. The self-calibrating inspection system includes: an inspection device configured to visually inspect or measure an article placed on a carrier; a motion actuator on which the inspection device is mounted, the motion actuator being configured to move the inspection device relative to the carrier along a predetermined motion trajectory; a calibration member fixedly positioned relative to the carrier; a distance sensor fixedly positioned relative to the inspection device and configured to sense a first distance between the distance sensor and the calibration member during the movement of the inspection device by the motion actuator; and a controller communicating with the motion actuator and the distance sensor and configured to determine, based on the first distance, a deviation between the actual motion trajectory of the inspection device and the predetermined motion trajectory, and to control the motion actuator to move the inspection device along a path substantially consistent with the predetermined motion trajectory based on the deviation.

Description

Technical Field

[0001] Embodiments of this disclosure generally relate to article inspection, and more specifically, to an article inspection system and a method for inspecting or measuring articles using the same, which is adapted to automatically correct the movement trajectory of the inspection device relative to the article to improve inspection accuracy. Background Technology

[0002] In conventional techniques, visual inspection devices are typically used to inspect or measure products or their components, for example, to check for quality defects (e.g., dents, gaps, etc.) or whether the dimensions of the products or their components are within acceptable limits.

[0003] Such inspections or measurements are usually performed by moving the inspection device relative to the item. However, in actual operation, the movement trajectory of the inspection device relative to the item often deviates from the expected trajectory, making it impossible to obtain the expected inspection or measurement results accurately, thus reducing the accuracy of the inspection or measurement. Summary of the Invention

[0004] This disclosure is made in order to overcome at least one of the above-mentioned and other problems and defects existing in the prior art.

[0005] According to one aspect of this disclosure, a self-calibrating inspection system is provided, comprising: an inspection device configured to visually inspect or measure an article placed on a carrier; a motion actuator mounted on the inspection device, the motion actuator being configured to move the inspection device along a predetermined motion trajectory relative to the carrier and the article placed thereon; a calibration member fixedly positioned relative to the carrier; a distance sensor fixedly positioned relative to the inspection device and configured to sense a first distance between the distance sensor and the calibration member during movement of the inspection device by the motion actuator; and a controller communicating with the motion actuator and the distance sensor and configured to determine, based on the first distance, a deviation between the actual motion trajectory of the motion actuator moving the inspection device and the predetermined motion trajectory, and to control the motion actuator to move the inspection device along a path substantially consistent with the predetermined motion trajectory based on the deviation.

[0006] In some embodiments, the controller is further configured to generate a motion compensation value based on the deviation, and adjust the actual motion trajectory of the motion actuator movement inspection device based on the motion compensation value to substantially match the predetermined motion trajectory.

[0007] In some embodiments, the distance sensor is fixedly mounted to the inspection device.

[0008] In some embodiments, a predetermined distance exists between the correction member and the predetermined motion trajectory, and the controller is configured to determine the deviation based at least on the first distance and the predetermined distance.

[0009] In some embodiments, the predetermined motion trajectory includes a straight line trajectory or a curved trajectory.

[0010] In some embodiments, the motion actuator includes a robot or a mobile robotic arm.

[0011] In some embodiments, the motion actuator, the correction member, and the carrier are mounted on the same workbench, or the carrier includes a workbench.

[0012] In some embodiments, the self-calibrating inspection system further includes an automated guided vehicle on which the workbench is positioned.

[0013] In some embodiments, the inspection apparatus includes an imaging device or a scanning device.

[0014] In some embodiments, the correction member includes a plate-shaped member extending in a direction substantially parallel to the predetermined motion trajectory.

[0015] According to another aspect of this disclosure, a method for inspecting an article using the self-calibrating inspection system described in any embodiment of this disclosure is also provided, comprising: placing the article on the carrier; moving an inspection device mounted thereon by a motion actuator to perform visual inspection or measurement of the article by the inspection device; sensing a first distance between the distance sensor and a calibration member by a distance sensor during the movement of the inspection device by the motion actuator; and determining a deviation between an actual movement trajectory of the motion actuator moving the inspection device and a predetermined movement trajectory based on the first distance, and controlling the motion actuator to move the inspection device along a path substantially consistent with the predetermined movement trajectory based on the deviation. Attached Figure Description

[0016] The above and other aspects, features, and advantages of various embodiments of the present disclosure will become clearer from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0017] Figure 1 This is a perspective view schematically illustrating the configuration of a self-calibrating inspection system according to exemplary embodiments of the present disclosure;

[0018] Figure 2 This is a schematic side view of a self-calibrating inspection system according to an exemplary embodiment of the present disclosure;

[0019] Figure 3This is a top view schematically illustrating a portion of the configuration of a self-calibrating inspection system according to an exemplary embodiment of the present disclosure, showing a calibration member and a distance sensor mounted to the inspection device;

[0020] Figure 4 This is a schematic graph illustrating the motion trajectory of an inspection device according to an exemplary embodiment of the present disclosure, showing the correction to the actual motion trajectory of the inspection device; and

[0021] Figure 5 This is a flowchart schematically illustrating a method for visually inspecting or measuring an article using a self-calibrating inspection system according to exemplary embodiments of the present disclosure. Detailed Implementation

[0022] The embodiments of this disclosure will now be described in detail with reference to the accompanying drawings. In this specification, identical or similar components are indicated by identical or similar reference numerals. The following description of various embodiments of this disclosure with reference to the accompanying drawings is intended to illustrate the overall concept of this disclosure and should not be construed as a limitation thereof.

[0023] Furthermore, in the following detailed description, numerous specific details are set forth for ease of explanation to provide a thorough understanding of embodiments of the present disclosure. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and apparatuses are illustrated to simplify the figures.

[0024] Exemplary embodiments of the present disclosure provide a self-calibrating inspection system adapted to automatically correct motion trajectories, thereby inspecting articles with high accuracy, such as visually inspecting or measuring products or their components.

[0025] like Figure 1-3 As shown, the self-calibrating inspection system 100 includes an inspection device 110 for visually inspecting or measuring an article 10 placed on a carrier 11 or a fixed device. As an example, the inspection device 110 may include an imaging device or a scanning device, such as a 3D camera or a 3D scanner, which can be used to acquire images of the article for visual inspection, dimensional measurement, etc., based on the images.

[0026] like Figure 1-3 As shown, the self-calibrating inspection system 100 also includes a motion actuator 120, on which an inspection device 110 is mounted. The motion actuator 120 can move the inspection device 110 along a predetermined motion trajectory relative to the carrier 11 or the article 10 placed thereon, so that the inspection device 110 can inspect or measure the article. As an example, the motion actuator 120 may include a robot or a mobile robotic arm.

[0027] According to an exemplary embodiment of this disclosure, the self-calibrating inspection system 100 further includes a distance sensor 130 and a calibration member 150. The calibration member 150 is fixedly positioned relative to the carrier 11, i.e., at least during the movement of the inspection device 110 by the motion actuator 120, the calibration member 150 maintains a fixed positional or spacing relationship with the carrier 11 or the article 10 placed thereon. For example, a predetermined or expected positional or spacing relationship between the calibration member 150 and the predetermined motion trajectory of the inspection device 110 can be determined based on the positioning of the calibration member 150 and the predetermined motion trajectory of the inspection device 110. In some examples, the position or spacing of the calibration member 150 relative to the carrier 11 can be adjusted before inspection or measurement to accommodate the inspection of different articles. Exemplarily, such as... Figure 1-2 As shown, the correction member 150 may include a plate-shaped member that extends in a direction substantially parallel to the predetermined motion trajectory.

[0028] The distance sensor 130 is fixedly positioned relative to the inspection device 110, allowing it to move together with or synchronously with the inspection device 110. In other words, the distance sensor 130 maintains a fixed position or spacing relative to the inspection device 110, such that as the inspection device 110 moves along one trajectory, the distance sensor 130 moves along a corresponding other trajectory, maintaining a fixed position or spacing between the two trajectories. As an example, the distance sensor 130 can be fixedly mounted to the inspection device 110, for instance, on the side of the inspection device 110 facing the correction member 150.

[0029] Distance sensor 130 is used to sense a first distance d between the distance sensor 130 and the calibration member 150 during the movement of the inspection device 110 by the motion actuator 120 (e.g., along direction R). Figure 3 As shown. As an example, the distance sensor may include optical sensors such as infrared sensors, laser rangefinders, ultrasonic sensors, etc. Since the distance sensor 130 is fixedly positioned relative to the inspection device 110 or the two maintain a fixed position or distance relationship, a second distance between the inspection device 110 and the correction member 150 during movement can be determined based on the first distance d between the distance sensor 130 and the correction member 150. The second distance corresponds to the actual movement trajectory of the inspection device 110.

[0030] The self-calibrating inspection system 100 also includes a controller 170, such as a processor, which communicates with the motion actuator 120 and the distance sensor 130 to determine, based on a first distance d, the deviation between the actual movement trajectory of the motion actuator 120 moving the inspection device 110 and a predetermined movement trajectory, and then controls the motion actuator 120 to move the inspection device 110 along a path substantially consistent with the predetermined movement trajectory based on this deviation, ensuring the accuracy of the inspection device's movement. The distance sensor 130 can measure the distance in real time, and the controller 170 can control the movement of the motion actuator 120 on the inspection device 110 in real time based on the determined deviation. Exemplarily, the distance sensor can measure the distance continuously or intermittently, depending on, for example, the actual inspection needs, inspection or movement accuracy requirements, etc.

[0031] As an example, this deviation can be characterized by the change in the actual distance between the distance sensor 130 or the inspection device 110 and the correction member 150 during movement, or it can be obtained by comparing the actual distance between the distance sensor 130 or the inspection device 110 and the correction member 150 during movement, obtained based on measurements from the distance sensor 130, with a predetermined or expected distance between the correction member 150 and the predetermined motion trajectory.

[0032] The controller 170 can generate a motion compensation value based on the aforementioned deviation, and adjust the actual motion trajectory of the motion actuator 120 to substantially match or correspond to the predetermined motion trajectory. As an example, the motion compensation value may include a reverse motion displacement for adjusting the motion trajectory of the inspection device. For instance, when a distance sensor measurement determines that the inspection device deviates from the predetermined motion trajectory by a distance, the controller can generate a corresponding reverse displacement compensation value that is approximately the same as that distance, controlling the motion actuator to move the inspection device by a distance substantially equal to the reverse displacement compensation value in the opposite direction, thereby returning the movement of the inspection device to the predetermined motion trajectory.

[0033] exist Figure 4 The curve in (a) shows an example of the actual motion trajectory of the motion actuator movement inspection device, which deviates from the expected or predetermined motion trajectory and exhibits the aforementioned deviation, as shown by the dashed line; Figure 4 The curve in (b) shows the motion compensation value generated by the controller, which is approximately the same in magnitude but opposite in direction to this deviation or offset; thus, based on this motion compensation value, the actual motion trajectory of the motion actuator movement inspection device is adjusted to substantially match or correspond to the predetermined motion trajectory, such as... Figure 4As shown in (c) in the figure. In the illustrated embodiment, the case where the predetermined motion trajectory of the inspection device is a straight line is used as an example. However, the predetermined motion trajectory of the inspection device is not limited to this. It can also be set according to the inspection needs and may include a curved trajectory.

[0034] In such Figure 1 and 2 In the illustrated embodiment, the motion actuator 120, the correction member 150, and the carrier 11 are mounted on the same worktable 140. In other examples, the carrier itself may include a worktable or define an inspection area; alternatively, a carrier may not be required, and the item to be inspected may be placed directly within the inspection area of ​​the worktable 140, in which case the correction member is fixedly positioned relative to the inspection area during movement of the inspection device.

[0035] In the illustrated embodiment, the self-calibrating inspection system 100 also includes an automated guided vehicle (AGV) 160 or other suitable mobile carrier, on which the workbench 140 can be positioned. A controller 170 may be disposed on the AGV 160, and in some examples, the controller 170 may also be used to control the movement of the AGV 160, thereby controlling the AGV 160 or the self-calibrating inspection system 100 to move to a suitable position according to inspection requirements.

[0036] Exemplary embodiments of this disclosure also disclose a method for inspecting articles using such a self-calibrating inspection system, such as... Figure 5 As shown, the method mainly includes the following steps:

[0037] S101: Place the item 10 to be inspected onto the vehicle 11;

[0038] S102: The inspection device 110 mounted thereon is moved by the motion actuator 120 so that the inspection device 110 can perform visual inspection or measurement on the article 10, such as acquiring an image of the article or detecting defects, dimensions, etc. of the article.

[0039] S103: During the movement of the motion actuator 120 and the inspection device 110, a first distance d between the distance sensor 130 and the calibration member 150 is sensed by the distance sensor 130 (e.g., in real time); and

[0040] S104: For example, via controller 170, the deviation between the actual motion trajectory of motion actuator 120 and the predetermined motion trajectory of inspection device 110 is determined based on the first distance d, and based on the deviation (e.g., in real time), motion actuator 120 is controlled to move inspection device 110 along a path substantially consistent with the predetermined motion trajectory.

[0041] Although embodiments of the present disclosure have been shown and described, it will be understood by those skilled in the art that variations may be made to these embodiments without departing from the principles and spirit of the present disclosure, the scope of which is defined by the appended claims and their equivalents. Furthermore, it should be noted that, unless otherwise specified, the terms “comprising,” “including,” and “having” as used herein do not exclude other elements or steps. Additionally, any reference numerals in the claims should not be construed as limiting the scope of the present disclosure.

Claims

1. A self-calibrating inspection system (100), comprising: Inspection device (110) configured to perform visual inspection on an article (10) placed on a vehicle (11); Motion actuator (120), inspection device mounted on the motion actuator, the motion actuator being configured to move the inspection device along a predetermined motion trajectory relative to the carrier and the item placed thereon during the visual inspection of the item (10) placed on the carrier (11); A correction member (150) is spaced apart from the carrier and is fixedly positioned relative to the carrier at a fixed distance during the movement of the inspection device by the motion actuator, such that a predetermined distance exists between the correction member and the predetermined motion trajectory, and the position or distance of the correction member relative to the carrier can be adjusted before inspection; A distance sensor (130) is spaced apart from the calibration member and fixedly positioned relative to the inspection device, and is configured to sense a first distance between the distance sensor and the calibration member during the movement of the inspection device by the motion actuator; and A controller (170), which communicates with the motion actuator and the distance sensor, is configured to determine, based on a comparison of the first distance and the predetermined distance, the deviation between the actual motion trajectory of the motion actuator moving the inspection device and the predetermined motion trajectory, and based on this deviation, control the motion actuator to move the inspection device along a path substantially consistent with the predetermined motion trajectory, wherein... The controller is further configured to generate a motion compensation value based on the deviation, and adjust the actual motion trajectory of the motion actuator movement inspection device based on the motion compensation value to substantially match the predetermined motion trajectory.

2. The self-calibrating inspection system according to claim 1, wherein, The distance sensor is fixedly mounted to the inspection device.

3. The self-calibrating inspection system according to any one of claims 1-2, wherein the predetermined motion trajectory includes a straight line trajectory or a curved trajectory.

4. The self-calibrating inspection system according to any one of claims 1-2, wherein the motion actuator comprises a robot.

5. The self-calibrating inspection system according to any one of claims 1-2, wherein the motion actuator comprises a movable robotic arm.

6. The self-calibrating inspection system according to any one of claims 1-2, wherein, The motion actuator, the correction component, and the carrier are mounted on the same workbench (140), or the carrier includes a workbench.

7. The self-calibrating inspection system according to any one of claims 6 further includes an automated guided vehicle, on which the workbench is positioned.

8. The self-calibrating inspection system according to any one of claims 1-2, wherein, The inspection device includes an imaging device.

9. The self-calibrating inspection system according to any one of claims 1-2, wherein, The correction component includes a plate-shaped component extending in a direction substantially parallel to the predetermined motion trajectory.

10. A method for inspecting articles using the self-calibrating inspection system according to any one of claims 1-9, comprising: Place the item on the vehicle; During the visual inspection of the item (10) placed on the carrier (11) by the inspection device, the inspection device mounted thereon is moved by the motion actuator; During the movement inspection of the motion actuator, a first distance between the distance sensor and the correction member is sensed by a distance sensor, the correction member being fixedly positioned relative to the carrier with a fixed distance relationship during the movement inspection of the motion actuator. as well as Based on the first distance, the deviation between the actual movement trajectory of the motion actuator and the predetermined movement trajectory is determined, and based on the deviation, the motion actuator is controlled to move the inspection device along a path that is substantially consistent with the predetermined movement trajectory.

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