Visual inspection system and method using light sources of different wavelengths

Abstract

A system includes a station for supporting a workpiece having one or more welds and / or surface features, and a first visual sensing assembly and a second visual sensing assembly. The first assembly is configured to illuminate the workpiece and generate an image of the one or more welds and / or surface features. The first assembly includes a first light source configured to emit light having a first wavelength and a first sensor configured to detect light having the first wavelength reflected by the workpiece. The second assembly is configured to illuminate the workpiece and generate an image of the one or more welds and / or surface features. The second assembly includes a second light source configured to emit light having a second wavelength and a second sensor configured to detect light having the second wavelength reflected by the workpiece. Other example systems and methods are also disclosed.

Description

[0001] Priority The information provided in this section is for the purpose of presenting the context of the present disclosure generally. The work of the presently named inventors - to the extent it is described in this section - and aspects of this description that may not otherwise be eligible as prior art at the time of filing are neither expressly nor implicitly regarded as prior art against the present disclosure.

[0002] The present disclosure relates to vision inspection systems and methods, and more particularly to vision inspection systems and methods for using light sources of different wavelengths to obtain images for inspecting welds and / or surface features such as laser welds, arc welds, electron beam welds, adhesive beads, textured surfaces, and the like.

[0003] Welds can be used to join two or more components in automotive and other applications. The width of a laser weld can be as narrow as 1 mm, and the concavity can be as deep as 3 mm to 6 mm. Inspection systems are sometimes used to analyze welds. Summary of the Invention

[0004] A vision inspection system for welds and / or surface features includes a scanning station for supporting a workpiece including one or more welds and / or surface features, a first vision sensing assembly, and a second vision sensing assembly. The first vision sensing assembly is configured to illuminate the workpiece and generate an image of one or more welds and / or surface features of the workpiece. The first vision sensing assembly includes a first light source configured to emit light having a first wavelength toward the workpiece and a first sensor configured to detect light having the first wavelength reflected by the workpiece. The second vision sensing assembly is configured to illuminate the workpiece and generate an image of one or more welds and / or surface features of the workpiece. The second vision sensing assembly includes a second light source configured to emit light having a second wavelength toward the workpiece and a second sensor configured to detect light having the second wavelength reflected by the workpiece. The second wavelength is different from the first wavelength.

[0005] In other features, the first light source and the second light source are positioned adjacent to each other.

[0006] In other features, the distance between the first light source and the second light source is a fixed value of 10 millimeters or less.

[0007] In other features, the first light source and the second light source are positioned in a plane extending parallel to the workpiece.

[0008] In other features, the first light source is a laser configured to emit electromagnetic radiation at the first wavelength.

[0009] Among other features, the laser is a blue laser.

[0010] Among other features, the first sensor includes a camera.

[0011] Among other features, the first sensor includes a filter configured to only allow light of a first wavelength to pass through.

[0012] Among other features, the laser is a first laser and the second light source is a second laser configured to emit electromagnetic radiation at a second wavelength.

[0013] Among other features, the second laser is a red laser.

[0014] Among other features, the second sensor includes a camera.

[0015] Among other features, the second sensor includes a filter configured to only allow light of a second wavelength to pass through.

[0016] Among other features, the vision inspection system further includes a control module in communication with the first vision sensing assembly and the second vision sensing assembly. The control module is configured to control the first light source and the second light source to turn on simultaneously.

[0017] Among other features, the control module is configured to combine the image data from the first sensor and the image data from the second sensor based on the relative speed between the workpiece and the first vision sensing assembly and the second vision sensing assembly and the distance between the first light source and the second light source.

[0018] Among other features, the vision inspection system further includes a robotic arm mounted to the first vision sensing assembly and the second vision sensing assembly. The robotic arm is configured to move the first vision sensing assembly and the second vision sensing assembly above one or more welds and / or surface features of the workpiece.

[0019] Among other features, the vision inspection system further includes a conveyor configured to move the workpiece into the fields of view of the first vision sensing assembly and the second vision sensing assembly.

[0020] A method for inspecting welds and / or surface features using a first vision sensing assembly and a second vision sensing assembly is disclosed. The first vision sensing assembly includes a first light source and a first sensor, and the second vision sensing assembly includes a second light source and a second sensor. The method includes: illuminating a workpiece including one or more welds and / or surface features with light having a first wavelength emitted from the first light source, illuminating the workpiece with light having a second wavelength different from the first wavelength emitted from the second light source, generating a first image using the first sensor based on the light having the first wavelength, generating a second image using the second sensor based on the light having the second wavelength, and combining the first image generated by the first sensor and the second image generated by the second sensor.

[0021] Among other features, the first light source is a laser configured to emit light at the first wavelength, the second light source is a laser configured to emit light at the second wavelength, the first sensor includes a camera, and the second sensor includes a camera.

[0022] Among other features, the method further includes filtering the light emitted at the first wavelength via a first filter and filtering the light emitted at the second wavelength via a second filter.

[0023] Among other features, combining the first image generated by the first sensor and the second image generated by the second sensor includes: combining the first image and the second image based on the relative speed between the workpiece and the first and second vision sensing assemblies and the distance between the first and second light sources.

[0024] Further applicable fields of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure will be more fully understood from the detailed description and the drawings, in which: Figure 1 is a functional block diagram of an example vision inspection system including two vision sensing assemblies with light sources having different wavelengths in accordance with the present disclosure; Figure 2 is a functional block diagram of another example vision inspection system including two vision sensing assemblies and a movable conveyor in accordance with the present disclosure; Figure 3 is a functional block diagram of another example vision inspection system including two vision sensing assemblies and a movable robotic arm in accordance with the present disclosure; and Figures 4 to 5 is a flowchart of an example control process for inspecting welds and / or surface features in accordance with the present disclosure.

[0026] In the drawings, reference numerals may be reused to identify similar and / or identical elements. DETAILED DESCRIPTION

[0027] Weld joints can be used to join components in a variety of applications, including automotive applications. In such an example, an inspection system can be employed to capture machine vision images of the weld joint and then analyze the weld joint. The quality of the captured images can be affected by different conditions. For example, the quality of a 3D surface, such as a laser weld joint surface, can be affected by high surface gradients or fluctuations due to depressions or bulging. In such an example, depressions in the surface can generate signal-deprived regions in the image data, such as occlusions or shadows. Additionally, in some examples, the quality of the surface can be affected by the type of material of the components being welded. For example, depending on the material, there may be a high reflectivity and low absorption ratio of the light emitted from the inspection system by the material surface, which can result in data loss in the image. As an example, the weld joint surface associated with a busbar (e.g., in an electric vehicle battery pack) may contain pinholes and spatter, which can result in data loss in the image. In such an example, the busbar material can be aluminum or copper, which have different reflectivities for common emitted light (e.g., blue, green, and red lasers).

[0028] The visual inspection system and method according to the present disclosure provide the following solution: the solution obtains high-quality imaging for weld joint and / or surface feature analysis and inspection by using at least two visual sensing assemblies with light sources of different wavelengths, such that the visual sensors in the assemblies can compensate for each other in terms of visibility and reflectivity. In doing so, these solutions overcome the challenges explained above caused by the visibility of the weld joint morphology and the reflectivity of the material of interest.

[0029] Now referring to Figure 1 , a block diagram of an example visual inspection system 100 is presented for a laser weld joint. Although Figure 1 the visual inspection system 100 and / or other systems herein are described with respect to laser weld joints, it should be appreciated that the systems herein can be applicable to other types of weld joints and / or surface features, such as arc weld joints, electron beam weld joints, adhesive beads, textured surfaces, etc. Additionally, the visual inspection system 100 and / or other systems herein can be applicable to weld joint inspection in any suitable application (such as automotive applications).

[0030] As Figure 1As shown, the vision inspection system 100 generally includes a scanning station 102 and two vision sensing assemblies 104, 106. The scanning station 102 includes a platform 112 to support a workpiece 108 having one or more laser welds and / or surface features 110. In various embodiments, the surface features 110 may include, for example, pinholes, spatter, and / or some surface variations in the workpiece 108. In Figure 1 the example, one surface feature is shown as a dome-shaped shape. Each vision sensing assembly 104, 106 illuminates the workpiece 108 and generates an image of one or more laser welds and / or surface features 110 of the workpiece 108. For example, as Figure 1 shown, each vision sensing assembly 104, 106 emits light from a projection window toward the workpiece 108 (e.g., the laser weld and / or surface feature 110), and detects the light reflected from the workpiece 108 (e.g., the laser weld and / / or surface feature 110). Each vision sensing assembly 104, 106 and / or a control module communicating with the vision sensing assemblies 104, 106 can then generate an image (e.g., a 3D surface depth map image, etc.) based on the reflected light, as further explained herein.

[0031] In Figure 1 the example, the vision sensing assemblies 104, 106 emit light at different wavelengths. For example, the vision sensing assembly 104 can emit light at a wavelength corresponding to one color, and the vision sensing assembly 106 can emit light at a different wavelength corresponding to another color. In such an example, the color (and thus the wavelength) can be selected based on, for example, the material type of the workpiece 108. Then, each vision sensing assembly 104, 106 can detect only the reflected light corresponding to the light emitted at the respective wavelength, as further explained below. For example, if the vision sensing assembly 104 emits red light, the assembly can detect only red light, and if the vision sensing assembly 106 emits blue light, the assembly can detect only blue light.

[0032] Figure 1 The workpiece 108 and / or any other workpiece herein can be any suitable welded component. For example, the workpiece 108 can be a bus bar (e.g., having pinholes and spatter) or another welded component. In such an example, the workpiece 108 can be a component of a vehicle. Although Figure 1 the workpiece 108 is shown as having a generally dome-shaped shape, it should be appreciated that the workpiece 108 can have any suitable shape and / or size.

[0033] In Figure 1In the example, the workpiece 108 is typically positioned within the fields of view of two vision sensing assemblies 104, 106. For example, the vision sensing assemblies 104, 106 are typically located in a plane parallel to and above the workpiece 108 (relative to the z-direction indicated by arrow 154). With this configuration, the vision sensing assembly 104 includes a transmitted light field of view 114 directed at the workpiece 108 represented by lines having a dashed configuration and a detection field of view 116 directed at the workpiece 108 represented by lines having a long dashed configuration. Similarly, the vision sensing assembly 106 includes a transmitted light field of view 118 directed at the workpiece 108 represented by lines having a dash-dot-dashed configuration and a detection field of view 120 directed at the workpiece 108 represented by lines having a dash-dot-dot-dashed configuration.

[0034] In such an example, by moving the workpiece 108 and / or the vision sensing assemblies 104, 106, the workpiece 108 can be positioned within the fields of view of the vision sensing assemblies 104, 106. For example, the platform 112 supporting the workpiece 108 can be dynamic or stationary. If dynamic, the platform 112 can be a conveyor for moving the workpiece 108 supported thereon relative to the vision sensing assemblies 104, 106, as further explained below. In such an example, the platform 112 can move the workpiece 108 in any suitable direction, such as the x-direction indicated by arrow 150, the y-direction indicated by arrow 152, etc. In other examples, the platform 112 can typically be static, and the vision sensing assemblies 104, 106 can be moved relative to the workpiece 108 on the platform 112 (e.g., via one or more robotic arms, etc.), as further explained below.

[0035] In either case, the two vision sensing assemblies 104, 106 cover the region of interest associated with the workpiece 108. For example, the vision sensing assemblies 104, 106 project light and detect light reflected from the workpiece 108 across the region of the workpiece 108 intended for inspection. In such an example, the region of interest can include the surface of the workpiece 108 and / or portions within the workpiece 108 (e.g., within the outer surface of the workpiece 108).

[0036] Figure 2 Depicts an example vision inspection system 200 similar to Figure 1 the vision inspection system 100, but including additional components. For example, the vision inspection system 200 includes vision sensing assemblies 204, 206, such as laser profilers, that emit light at different wavelengths toward the workpiece 108 (e.g., surface feature 110) and detect the light reflected from the workpiece 108 (e.g., surface feature 110), as described above with respect to Figure 1as explained by the visual sensing assemblies 104, 106.

[0037] More specifically, the visual sensing assemblies 204, 206 respectively include light sources 222, 228. In Figure 2 the example, the light sources 222, 228 are lasers for emitting electromagnetic radiation. For example, the light source 222 can project a laser line 214, and the light source 228 can project a laser line 218, as Figure 2 shown.

[0038] In Figure 2 the example, the light sources 222, 228 emit light at different wavelengths. For example, the light source 222 of the visual sensing assembly 204 can be a blue laser that emits light at a wavelength in the range of approximately 400 nanometers (nm) to approximately 500 nm (e.g., at 405 nm, 450 nm, 458 nm, 488 nm, etc.). Additionally, the light source 228 of the visual sensing assembly 206 can be a red laser that emits light at a wavelength in the range of approximately 600 nm to approximately 810 nm (e.g., at 638 nm, 650 nm, 670 nm, 808 nm, etc.). In other examples, the light sources 222, 228 can be other suitable types of light that emit different wavelengths, including other suitable types of lasers (e.g., green lasers, etc.).

[0039] As Figure 2 shown, the visual sensing assemblies 204, 206 also respectively include sensors 224, 230. In this example, the sensors 224, 230 are cameras or any other suitable type of device for detecting the light 216, 220 reflected by the workpiece 108 (e.g., surface feature 110). For example, the workpiece 108 (e.g., surface feature 110) may cause distortion in the laser lines 214, 218, which can be detected and recorded by the camera. For example, in various embodiments, some of the emitted light from each of the light sources 222, 228 is reflected off the workpiece 108, and some of the emitted light is absorbed by the emitted light, depending on the material type of the workpiece 108, the color of the workpiece 108, the color (e.g., wavelength) of the emitted light, etc.

[0040] In some examples, the sensors 224, 230 detect the reflected light 216, 220 at wavelengths associated with the light sources 222, 228. For example, the sensor 224 of the visual sensing assembly 204 can detect the reflected light at a wavelength associated with the light source 222. Additionally, the sensor 230 of the visual sensing assembly 206 can detect the reflected light at a wavelength associated with the light source 228.

[0041] In various embodiments, the vision sensing assemblies 204, 206 may detect only reflected light at a specific wavelength or wavelength range. For example and as Figure 2 shown, the vision sensing assemblies 204, 206 may include filters 226, 232 respectively, for filtering light emitted at a specific wavelength, thereby allowing only light at a specific wavelength to pass therethrough. For example, if the light source 222 is a blue laser emitting light at a wavelength of 450 nm, the filter 226 may filter out light at different wavelengths (such as between 600 nm and 810 nm, etc.). In other words, the filter 226 allows only light at a wavelength of 450 nm (or within a defined distance above / below 450 nm) to pass through to reach the sensor 224. The filter 232 for the sensor 230 may operate in a similar manner, but for the light source 228.

[0042] In Figure 2 the example of, the vision sensing assemblies 204, 206 may be mounted head-to-head. With this arrangement, the light sources 222, 228 are positioned adjacent to each other, as Figure 2 shown. In this example, the laser lines 214, 218 emitted from the light sources 222, 228 are separated by a distance d (represented by the distance 234 in Figure 2 ). In various embodiments, the distance 234 between the laser lines 214, 218 (and more generally, the light sources 222, 228) may be a fixed value such as 10 millimeters (mm) or less, for example. For example, the distance 234 may be any suitable value, such as 10 mm, 7 mm, 5 mm, 3 mm, etc. In some examples, it may be desirable to minimize the distance 234 as much as possible. The distance 234 may be determined in various ways. For example, the distance 234 may be determined by the required visibility and reflectivity compensation between the vision sensing assemblies 204, 206 to achieve an optimized quality of the generated composite image, as further explained below.

[0043] As Figure 2 shown, the workpiece 108 is supported by the conveyor 208. In this example, the conveyor 208 moves in a linear direction 236 below the light sources 222, 228 so that the workpiece 108 passes through the laser lines 214, 218. Thus, the conveyor 208 moves the workpiece 108 into the field of view of the vision sensing assemblies 204, 206. In other examples, the workpiece 108 may remain stationary while the vision sensing assemblies 204, 206 move relative to the workpiece 108, as further explained herein.

[0044] In various embodiments, the vision sensing assemblies 204, 206 are generally located in a plane parallel to the workpiece 108. For example, as Figure 2As shown, the vision sensing assemblies 204, 206, including their light sources 222, 228, are located in a horizontal plane above the workpiece 108. In this example, the horizontal plane extends generally parallel to the plane in which the workpiece 108 lies. In other words, the horizontal plane extends generally parallel to Figure 2 the conveyor 208 in Figure 2 . Although the light sources 222, 228 of

[0045] are shown in a specific position (e.g., above) relative to the workpiece 108, it should be appreciated that in other embodiments, the light sources 222, 228 may be located in other positions relative to the workpiece 108. Figure 2 As Figure 2 shown, the vision inspection system 200 further includes a control module 238 in communication with the vision sensing assemblies 204, 206. More specifically,

[0046] the control module 238 of Figure 2 transmits control signals 240, 242 to the light sources (e.g., lasers) 222, 228 and receives signals 244, 246 from the sensors (e.g., cameras) 224, 230.

[0047] In the example of

[0048] Additionally and / or alternatively, the control module 238 may combine the images based on other factors. For example, the control module 238 may combine the images based on the material type of the workpiece 108. In such an example, depending on the material type, the control module 238 may designate one of the images in the images (e.g., generated by the sensor 224) as the primary source for generating the synthetic image, and designate another image (e.g., generated by the sensor 230) as the secondary source for generating the synthetic image.

[0049] For example, when the surface of the workpiece 108 is aluminum, a specific color (e.g., blue) may be more suitable for generating an image with higher contrast than other colors (e.g., red). In such an example, if the workpiece 108 is aluminum or includes aluminum on its surface, the control module 238 may consider the image from the sensor 224 (or another sensor that detects the reflected blue laser) as the control or primary image source, and consider the image from the sensor 230 as the secondary or supplementary image source. With this configuration, when the data from the primary image source is insufficient, such as under conditions like occlusion, shadow effects, etc., the supplementary image source from the sensor 230 can be utilized. Conversely, when the surface of the workpiece 108 is copper, a specific color (e.g., red) may be more suitable for generating an image because copper has a high absorption ratio for other colors. Thus, if the workpiece 108 is copper or includes copper on its surface, the control module 238 may consider the image from the sensor 230 (or another sensor that detects the reflected red laser) as the control image source, and consider the image from the sensor 224 as the supplementary image source (e.g., for compensation when the data from the primary image source is insufficient).

[0050] In various embodiments, the primary-secondary relationship may be implemented in other scenarios. For example, in some embodiments, the workpiece 108 may include a mixture of materials. In such an example, the control module 238 may still consider the image from one of the vision sensing assemblies 204, 206 as the primary image source, and consider the other image from the other vision sensing assembly 204, 206 as the supplementary image source. In such an example, this designation may be based on the amount of different materials in the workpiece 108, the location of the materials in the workpiece 108, etc. Additionally, in some examples, the designation between the primary image source and the supplementary image source may change when scanning the workpiece 108 or between different scans.

[0051] In some examples, the control module 238 may implement a weighting function when combining the images. For example, if the workpiece 108 includes a mixture of materials, when generating the synthetic image, the control module 238 may consider one of the images as being more influential (e.g., more weight is applied) than the other image.

[0052] In other examples, the control module 238 may treat the two images equally. For example, if the material type of the workpiece 108 has the same reflectance characteristics for different wavelengths (or for different colors), the control module 238 may treat the two images equally. In such an example, the control module 238 may combine the images based on the relative speed and the distance (d) 234, as explained above.

[0053] Figure 3 Depicts a visual inspection system 300 similar to Figure 2 the visual inspection system 200, but including a robotic arm. For example, the visual inspection system 300 includes Figure 1 visual sensing assemblies 204, 206 having light sources (such as lasers) 222, 228, sensors (such as cameras) 224, 230, and filters 226, 232,

[0054] In Figure 3 the example, the robotic arm 348 may be configured to move the visual sensing assemblies 204, 206 in one or more directions (such as in the x, y, and / or z directions). In such an example, the robotic arm 348 may be controlled by a control module (such as Figure 2 the control module 238, etc.) based on one or more inputs (such as user input, sensed input, etc.). With this configuration, the robotic arm 348 may move the visual sensing assemblies 204, 206 above the workpiece 108, which has surface features 110 and is supported by a platform 308, which may be movable or may not be movable.

[0055] Figures 4 to 5 Illustrates example control processes 400, 500 for inspecting welds and / or surface features. In Figures 4 to 5 the example, the control processes 400, 500 may be implemented using Figure 2 the visual inspection system 200. Although the example control processes 400, 500 are described with respect to the Figure 2 visual inspection system 200 including the control module 238, any one of the control processes 400, 500 may be employed by another suitable visual inspection system (such as other visual inspection systems disclosed herein).

[0056] In Figure 4 it, at 402, the control process 400 begins by emitting light from the light source 222 at a first wavelength and from the light source 228 at a second wavelength different from the first wavelength. For example and as explained above, Figure 2The control module 238 can trigger the light sources 222, 228 via control signals 240, 242 to be activated at the same time and / or frequency. In doing so, the light sources 222, 228 provide the emitted light (e.g., Figure 2 the laser lines 214, 218) into the field of view through which the workpiece 108 passes, and the workpiece 108 includes the weld(s) and / or surface features. Control then proceeds to 406, 408.

[0057] At 406, 408, sensors 224, 230 are utilized to generate independent images (e.g., image data). In such an example, the control module 238 can trigger the sensors 224, 230 to start collecting data at the same time and / or frequency. In various embodiments, the sensors 224, 230 can collect data (e.g., based on the reflected light from the workpiece 108) to generate independent images (e.g., 3D surface depth map images, etc.) when the workpiece 108 passes through the field of view of the sensors 224, 230, and then provide the data of the images to the control module 238 via signals 244, 246. Control then proceeds to 410.

[0058] At 410, the control module 238 combines the independent images into a composite image of the workpiece 108 or the region of interest associated with the workpiece 108. In such an example, the control module 238 can combine the independent images (e.g., the data representing the independent images) in any suitable manner, as explained herein. For example and as explained above, by designating one of the images in the image as the primary or control source and the other image as the secondary or supplementary source based on a weighting function, etc., the control module 238 can combine the images based on the type of material(s) present in the workpiece 108. Control can then end as Figure 4 shown, or return to 402 to scan the same workpiece or a different workpiece.

[0059] In Figure 5 , at 502, the control process 500 starts by determining whether a trigger signal has been received. If so, control proceeds to 504. If not, control returns to 502. At 504, one or more surfaces of the workpiece 108 are scanned using different light sources 222, 228 that emit light at different wavelengths, as explained herein. Control then proceeds to 506.

[0060] At 506, independent first and second images are obtained using sensors 224, 230. For example and as explained above, the sensors 224, 230 can collect data (e.g., the reflected light from the workpiece 108) to generate independent images (e.g., 3D surface depth map images, etc.) when the workpiece 108 passes through the field of view of the sensors 224, 230. Control then proceeds to 508.

[0061] At 508, it is determined whether the surface material of the workpiece 108 is a defined material, such as copper, aluminum, etc. In such an example, the control module 238 may receive an input indicating the material(s) of the workpiece surface, such as a user input indicating the type(s) of material, an input from a sensor(s) for detecting the type(s) of material, etc. If the surface material of the workpiece 108 is the same as the defined material, the control proceeds to 510, where the control module 238 sets the first image obtained by the sensor 224 as the primary image source and sets the second image obtained by the sensor 230 as the secondary image source, as explained herein. Conversely, if the surface material of the workpiece 108 is not the same as the defined material, the control proceeds to 512, where the control module 238 sets the second image obtained by the sensor 230 as the primary image source and sets the first image obtained by the sensor 224 as the secondary image source, as explained herein. The control then proceeds to 514.

[0062] At 514, the control module 238 combines the individual images into a composite image of the workpiece 108 or the region of interest associated with the workpiece 108, as explained herein. In such an example, the control module 238 combines the individual images based on the set primary image source and secondary image source. With this configuration, the primary image source can be used as the main control image, and the secondary image source can be used to compensate when necessary when the data from the primary image source is insufficient. The control can then end as Figure 5 shown, or return to 502 to scan the same workpiece or a different workpiece.

[0063] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application, or uses. The broad teachings of the present disclosure can be implemented in a variety of forms. Thus, while the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited since other modifications will become apparent upon study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method can be performed in a different order (or simultaneously) without changing the principles of the present disclosure. Additionally, although each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with each other are still within the scope of the present disclosure.

[0064] The spatial and functional relationships between components (e.g., between modules, circuit components, semiconductor layers, etc.) are described using various terms, including "connected," "joined," "coupled," "adjacent," "immediately adjacent," "on," "above," "below," and "disposed." Unless explicitly described as "direct," when the relationship between a first and a second component is described in the foregoing disclosure, the relationship can be a direct relationship in which no other intervening components exist between the first and the second components, but can also be an indirect relationship in which one or more intervening components (either spatially or functionally) exist between the first and the second components. As used herein, the phrase "at least one of A, B, and C" should be construed to mean a logical (A or B or C) using non-exclusive logical "or," and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0065] In the various figures, the direction of the arrows, as indicated by the arrowheads, generally indicates the information flow (such as data or instructions) of interest for that figure. For example, when component A and component B exchange various information, but the information transmitted from component A to component B is relevant to that figure, the arrow can point from component A to component B. This one-way arrow does not imply that no other information is transmitted from component B to component A. In addition, for the information sent from component A to component B, component B can send a request for that information or receive an acknowledgment to component A.

[0066] In this application, including the definitions below, the term "module" or the term "controller" may be replaced with the term "circuit." The term "module" may refer to, be part of, or include the following: application specific integrated circuit (ASIC); digital, analog, or mixed analog / digital discrete circuit; digital, analog, or mixed analog / digital integrated circuit; combinational logic circuit; field programmable gate array (FPGA); processor circuit (shared, dedicated, or grouped) that executes code; memory circuit (shared, dedicated, or grouped) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the foregoing, such as in a system-on-chip.

[0067] A module may include one or more interface circuits. In some examples, the interface circuit may include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module of the present disclosure may be distributed among multiple modules connected via the interface circuit. For example, multiple modules may allow load balancing. In a further example, a server (also referred to as remote or cloud) module may implement some functions on behalf of a client module.

[0068] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuit" encompasses a single processor circuit that executes some or all of the code from multiple modules. The term "group processor circuit" encompasses a processor circuit that executes some or all of the code from one or more modules in combination with additional processor circuits. References to multiple processor circuits encompass multiple processor circuits on separate die, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or combinations of the above. The term "shared memory circuit" encompasses a single memory circuit that stores some or all of the code from multiple modules. The term "group memory circuit" includes a memory circuit that stores some or all of the code from one or more modules in combination with additional memory.

[0069] The term "memory circuit" is a subset of the term "computer-readable medium". As used herein, the term "computer-readable medium" does not encompass non-transitory electrical or electromagnetic signals that are propagated through a medium (such as on a carrier wave); thus, the term "computer-readable medium" can be considered tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask ROM circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0070] The devices and methods described in this application can be implemented in part or in whole by a special-purpose computer created by configuring a general-purpose computer to execute one or more specific functions embodied in a computer program. The functional blocks, flowchart components, and other elements described above serve as a software specification that can be translated into a computer program by the routine work of a skilled technician or programmer.

[0071] A computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. A computer program can also include or rely on stored data. A computer program can encompass a basic input / output system (BIOS) that interacts with the hardware of a special-purpose computer, device drivers that interact with specific devices of a special-purpose computer, one or more operating systems, user applications, background services, background applications, and the like.

[0072] A computer program may include: (i) descriptive text to be parsed, such as HTML (HyperText Markup Language), XML (eXtensible Markup Language), or JSON (JavaScript Object Notation), (ii) assembly code, (iii) object code generated by a compiler from source code, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. By way of example only, the source code may be written using the syntax of a language including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Fortran, Perl, Pascal, Curl, OCaml, HTML5 (the fifth version of HyperText Markup Language), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK and

Claims

1. A visual inspection system for welds and / or surface features, the visual inspection system comprising: A scanning station for supporting a workpiece comprising one or more welds and / or surface features; A first vision sensing assembly configured to illuminate the workpiece and generate an image of the one or more welds and / or surface features of the workpiece, the first vision sensing assembly comprising a first light source configured to emit light having a first wavelength towards the workpiece and a first sensor configured to detect the light having the first wavelength reflected by the workpiece; And A second vision sensing assembly configured to illuminate the workpiece and generate an image of the one or more welds and / or surface features of the workpiece, the second vision sensing assembly comprising a second light source configured to emit light having a second wavelength towards the workpiece and a second sensor configured to detect the light having the second wavelength reflected by the workpiece; And Wherein the second wavelength is different from the first wavelength.

2. The visual inspection system according to claim 1, wherein the first light source and the second light source are positioned adjacent to each other.

3. The visual inspection system according to claim 1, wherein the first light source is a laser configured to emit electromagnetic radiation at a first wavelength.

4. The visual inspection system according to claim 3, wherein the laser is a blue laser.

5. The visual inspection system according to claim 3, wherein the first sensor comprises a filter configured to only allow light of the first wavelength to pass through.

6. The visual inspection system according to claim 3, wherein: The laser is a first laser; and The second light source is a second laser configured to emit electromagnetic radiation at a second wavelength.

7. The visual inspection system according to claim 6, wherein the second laser is a red laser.

8. The visual inspection system according to claim 6, wherein the second sensor comprises a filter configured to only allow light of the second wavelength to pass through.

9. The visual inspection system according to claim 1, further comprising a control module in communication with the first vision sensing assembly and the second vision sensing assembly, the control module configured to control the first light source and the second light source to turn on simultaneously.

10. The visual inspection system according to claim 9, wherein the control module is configured to combine image data from the first sensor and image data from the second sensor based on the relative speed between the workpiece and the first vision sensing assembly and the second vision sensing assembly and the distance between the first light source and the second light source.

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