Apparatuses and methods for inspecting surface

Abstract

To provide an apparatus capable of confirming a surface of a component and / or inspecting the surface of the component for foreign matter.SOLUTION: An apparatus 100 for inspecting a surface 120 includes a light source 106 and a camera 114. When a light beam 112 is generated by the light source 106, a centerline 142 of the light beam 112 is coincident with a line of sight 144 of the camera 114 when viewed in a direction perpendicular to a first plane that contains one of the centerline 142 of the light beam 112 or the line of sight 144 of the camera 114. The centerline 142 of the light beam 112 is parallel to the line of sight 144 of the camera 114 when viewed in a direction perpendicular to a first plane and perpendicular to a second plane including the centerline 142 of the light beam 112 and the line of sight 144 of the camera 114.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] An apparatus and method for inspecting a surface are described herein.

Background Art

[0002] During the manufacture and assembly of structures such as aircraft or their components, in some situations, it is desirable to identify surface finish characteristics. Further, if foreign object debris (FOD) is present on one or more surfaces of a structure, it is desirable to identify and remove that foreign object debris. Manually inspecting a structure to identify surface finish characteristics and / or identify and remove FOD is expensive and time-consuming. Further, in many cases, the spatial constraints imposed by the shape and dimensions of the structure make manual inspection difficult. Further, currently available automated solutions for surface inspection are expensive and generally inappropriate for use in confined spaces.

Summary of the Invention

[0003] Therefore, an apparatus and method aimed at addressing at least the above concerns would be useful.

[0004] [[ID=2-3]]

[0005] An apparatus for inspecting a surface is disclosed herein. The apparatus includes a light source configured to generate a light beam having a centerline. The apparatus also includes a camera having a line of sight. The apparatus further includes a microprocessor communicatively coupled to the camera. When the light beam is generated by the light source, the centerline of the light beam coincides with the line of sight of the camera when viewed in a direction perpendicular to a first plane including one of the centerline of the light beam or the line of sight of the camera. Further, when the light beam is generated by the light source, the centerline of the light beam is parallel to the line of sight of the camera when viewed in a direction perpendicular to the first plane and perpendicular to a second plane including the centerline of the light beam and the line of sight of the camera.

[0006] ​ The device enables the inspection of the surface of a part and / or the inspection of the surface of a part for foreign matter. The light source helps to generate shadows and reflections of light from textures within the surface and from foreign matter on the surface. The camera has a line of sight that coincides with the center line of the light ray when viewed in a direction perpendicular to a first plane containing either the center line of the light ray or the line of sight of the camera, and a line of sight that is perpendicular to the first plane and parallel to the center line of the light ray when viewed in a direction perpendicular to a second plane containing the center line of the light ray and the line of sight of the camera, thus allowing both the light source and the camera to be positioned close to the surface. The first plane falls within the page of Figure 4A, and the second plane falls within the page of Figure 3A. By positioning the light source close to the surface, shadows from textures and / or foreign matter are more easily magnified compared to the size of the textures and / or foreign matter, and reflections from textures and / or foreign matter are emphasized. By positioning the camera close to the surface, it becomes easier for the camera to capture images of the texture within the surface and / or the shadows cast by foreign objects on the surface, as well as the reflection of light from the texture within the surface and / or the foreign objects on the surface. The microprocessor facilitates the processing of the images captured by the camera to identify and / or classify the type of surface and foreign objects on the surface.

[0007] A method for inspecting a surface using the apparatus is also disclosed herein. The method includes the steps of (1) using a camera to capture an image of the surface including pixels of at least a portion of the surface while illuminating the surface with a light ray, and (2) comparing the pixel pattern of the image with an archived pixel pattern to determine whether the pixel pattern of the image matches one of an archived pixel pattern, each of which corresponds to one of a plurality of different types of surfaces. The acute angle between the center line of the light ray and the surface, when measured in a plane perpendicular to the surface and containing the center line, is between 0 and 30 degrees. At least one grayscale value of a pixel differs from at least one other grayscale value of a pixel. Thereafter, the pixels of the image generate a pixel pattern.

[0008] The first method allows for verification of the surface type of a part. Illuminating the surface with a ray helps to create shadows from the surface features (e.g., texture). The acute angle between the center line of the ray and the surface is between 0 and 30 degrees, which helps ensure that shadows are reliably created even from small surface features. At least one grayscale value of a pixel differs from at least one other grayscale value of a pixel, indicating the presence of a shadow-casting surface feature in the image. By comparing the resulting image's pixel pattern to an archived pixel pattern and determining whether the image's pixel pattern matches one of the archived pixel patterns, it can be confirmed that the surface type corresponds to the matching archived pixel pattern.

[0009] A method for inspecting a surface for foreign matter using the apparatus is further disclosed herein. The method includes (1) taking an image including pixels using a camera while illuminating the surface with a light ray, and (2) designating an object that protrudes from the surface and has a contact area with the surface as one of the foreign matter when the image includes at least one of a first subset of pixels corresponding to a first continuous region on the surface or a second subset of pixels corresponding to a second continuous region on the surface of an object. The acute angle between the centerline of the light ray and the surface, measured in a plane perpendicular to the surface and containing the centerline, is between 0 and 30 degrees. The first continuous region on the surface is continuous with the object. The first continuous region on the surface receives less energy from the light ray than a circumferentially closed portion of the surface. The circumferentially closed portion of the surface completely demarcates the first continuous region on the surface and the contact area of ​​the object with the surface by drawing a boundary line around it. A second continuous region on the surface of an object reflects more energy from light rays than a circumferentially closed portion of the object's surface. The circumferentially closed portion of the object's surface completely borders the second continuous region on the object's surface by drawing a boundary line around it.

[0010] The second method uses light rays from a light source and images captured by a camera to inspect the surface of a part for foreign objects, allowing for the identification and designation of foreign objects on the surface. The acute angle between the center line of the light ray and the surface is between 0 and 30 degrees, which helps ensure that shadows are cast from foreign objects on the surface and / or that light is reflected from foreign objects on the surface. The pixels of the first subset, when included in the image, provide a digital representation of the shadows cast from foreign objects on the surface. The pixels of the second subset, when included in the image, provide a digital representation of the light reflected from foreign objects. Therefore, when the image contains at least one of the pixels of the first subset or the pixels of the second subset, the presence of an object on the surface is identified and designated as a foreign object.

[0011] Next, please refer to the attached drawings. These are not necessarily drawn to a consistent scale, and similar reference letters indicate the same or similar parts across multiple drawings. The contents of the drawings are as follows: [Brief explanation of the drawing]

[0012] [Figure 1] This is a block diagram of an apparatus for inspecting surfaces according to one or more embodiments of the subject disclosed herein. [Figure 2] Figure 1 is a schematic perspective view of the apparatus according to one or more embodiments of the subject matter disclosed herein. [Figure 3A] This is a schematic elevation and side view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 3B] This is a schematic elevation and side view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 4A] This is a schematic top view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 4B] This is a schematic elevation and side view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 4C] This is a schematic perspective view of the surface of a component and foreign matter debris on the surface of a component according to one or more embodiments of the subject matter disclosed herein. [Figure 4D] This is a schematic elevation front view of surface foreign matter debris according to one or more embodiments of the subject matter disclosed herein. [Figure 5A] This is a schematic perspective view of the camera and the camera's field of view of the apparatus shown in Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 5B] This is a schematic perspective view of the camera and the camera's field of view of the apparatus shown in Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 5C] This is a perspective view of the camera and the camera's field of view of the apparatus shown in Figure 1 according to one or more embodiments of the subject disclosed herein. [Figure 6A] This is a schematic perspective view of the light source and the rays produced by the light source of the apparatus of Figure 1 according to one or more embodiments of the subject disclosed herein. [Figure 6B] This is a schematic perspective view of the light source and the rays produced by the light source of the apparatus of Figure 1 according to one or more embodiments of the subject disclosed herein. [Figure 6C] Figure 1 is a schematic perspective view of the light source and the light rays produced by the light source of the apparatus according to one or more embodiments of the subject disclosed herein. [Figure 7] Figure 1 is a schematic perspective view of the apparatus according to one or more embodiments of the subject matter disclosed herein. [Figure 8A] This is a schematic top view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 8B] This is a schematic top view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 8C] This is a schematic top view of the apparatus of Figure 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 9] This is a block diagram of a method according to one or more embodiments of the subject disclosed herein, which involves examining a surface using the apparatus of Figure 1 according to one or more embodiments of the subject disclosed herein. [Figure 10A]FIG. 10A and FIG. 10B are, collectively, block diagrams of a method according to one or more embodiments of the subject matter disclosed herein for inspecting a surface for foreign objects using the apparatus of FIG. 1 according to one or more embodiments of the subject matter disclosed herein. [Figure 10B] FIG. 10A and FIG. 10B are, collectively, block diagrams of a method according to one or more embodiments of the subject matter disclosed herein for inspecting a surface for foreign objects using the apparatus of FIG. 1 according to one or more embodiments of the subject matter disclosed herein.

DETAILED DESCRIPTION

[0013] Where solid lines exist in Figure 1 above connecting various elements and / or components, these solid lines may represent mechanical, electrical, fluid, optical, electromagnetic, and other connections, and / or combinations thereof. In this specification, “coupled” means directly and indirectly connected. For example, member A may be directly connected to member B, or indirectly connected via another member C, for example. It will be understood that not all relationships between the various elements disclosed are necessarily shown. Therefore, connections other than those illustrated in the block diagram may exist. Where dashed lines exist connecting blocks pointing to various elements and / or components, these dashed lines represent connections similar in function and purpose to those represented by solid lines. However, connections represented by dashed lines may be selectively provided or relate to alternative examples of the subject matter disclosed herein. Similarly, where elements and / or components are represented by dashed lines, they represent alternative examples of the subject matter disclosed herein. One or more elements shown by solid and / or dashed lines may be omitted from a particular example, provided that they do not deviate from the scope of the subject matter disclosed herein. Where environmental elements exist, they are shown by dotted lines. Hypothetical elements may also be shown for clarity. Those skilled in the art will understand that some of the features shown in Figure 1 can be combined in various ways without requiring the inclusion of other features described in Figure 1, other drawings, and / or accompanying disclosures (although one or more such combinations are not expressly shown herein). Similarly, additional features, not limited to the examples presented, can be combined with some or all of the features illustrated and described herein.

[0014] In FIGS. 9, 10A, and 10B mentioned above, a block may represent an operation and / or a part thereof, and lines connecting various blocks do not imply any particular order or dependency of these operations or parts thereof. Blocks shown by dashed lines indicate alternative operations and / or parts thereof. If there are dashed lines connecting various blocks, those dashed lines represent alternative dependencies of groups of operations or parts thereof. It should be understood that not all dependencies between various disclosed operations are necessarily represented. FIGS. 9, 10A, and 10B, which illustrate the operations of the (one or more) methods described herein, and the accompanying disclosure should not necessarily be construed as determining the order in which the operations are performed. Rather, one exemplary order is shown, but it should be understood that the sequence of operations can be modified where appropriate. Thus, a particular operation may be performed in a different order or simultaneously. Further, those skilled in the art will recognize that not all of the described operations need to be performed.

[0015] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the disclosed concept, but the concept may be practiced without some or all of these specific details. In other instances, well-known device and / or process details are omitted in order to avoid unnecessarily obscuring the description. Some concepts will be described in conjunction with specific examples, but it will be understood that these examples are not intended to be limiting.

[0016] Unless otherwise indicated, terms such as "first," "second," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or sequential requirements on the items they represent. Further, for example, if a "second" item is referred to, there is no requirement or exclusion of, for example, a "first" or smaller-numbered item, and / or a "third" or larger-numbered item.

[0017] Any reference in this specification to "one or more examples" means that one or more features, structures, or properties described in relation to that example are included in at least one embodiment. The phrase "one or more examples" found elsewhere in this specification may or may not refer to the same example.

[0018] In this specification, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function does not mean that it is actually capable of performing that particular function without any modification, and that it may only be capable of performing that particular function after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function is specifically selected, produced, implemented, used, programmed, and / or designed for the purpose of performing that particular function. In this specification, the expression "configured to" means an existing characteristic of the system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a particular function without further modification. Any system, apparatus, structure, article, element, component, or hardware described in this disclosure as “configured to” perform a particular function may also be described as “adapted to” and / or “operative to” perform that function, either additionally or alternatively.

[0019] Exemplary and non-exclusive examples of the subject matter of the inventions disclosed herein are provided below.

[0020] The following portion of this paragraph describes an embodiment 1 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figures 2-4B and 5A-8C. According to embodiment 1, an apparatus 100 for inspecting a surface 120 comprises a light source 106 configured to produce a ray 112 having a centerline 142. The apparatus 100 also comprises a camera 114 having a line of sight 144. The apparatus 100 further comprises a microprocessor 118 communicatively coupled to the camera 114. When the ray 112 is produced by the light source 106, the centerline 142 of the ray 112 coincides with the line of sight 144 of the camera 114 when viewed in a direction perpendicular to a first plane 150 containing either the centerline 142 of the ray 112 or the line of sight 144 of the camera 114. Furthermore, when the ray 112 is generated by the light source 106, the center line 142 of the ray 112 is perpendicular to the first plane 150 and parallel to the line of sight 144 of the camera 114 when viewed in a direction perpendicular to the second plane 152 which includes the center line 142 of the ray 112 and the line of sight 144 of the camera 114.

[0021] The apparatus 100 enables verification of the surface 120 of part 101 and / or inspection of the surface 120 of part 101 for foreign matter 130. The light source 106 helps to generate shadows and reflections of light from texture within the surface 120 and from foreign matter 130 on the surface 120. The camera 114 has a line of sight 144 that coincides with the center line 142 of the ray 112 when viewed in a direction perpendicular to a first plane 150 that includes either the center line 142 of the ray 112 or the line of sight 144 of the camera 114, and a line of sight 144 that is perpendicular to the first plane 150 and parallel to the center line 142 of the ray 112 when viewed in a direction perpendicular to a second plane 152 that includes the center line 142 of the ray 112 and the line of sight 144 of the camera 114, thus enabling both the light source 106 and the camera 114 to be positioned close to the surface 120. The first plane 150 is located within the page of Figure 4A, and the second plane 152 is located within the page of Figure 3A. By positioning the light source 106 close to the surface 120, the shadows from the texture and / or foreign matter 130 are more easily magnified compared to the size of the texture and / or foreign matter 130, and the reflections from the texture and / or foreign matter 130 are emphasized. By positioning the camera 114 close to the surface, it becomes easier for the camera 114 to capture images of the shadows cast by the texture and / or foreign matter 130 on the surface 120 and the reflections from the texture and / or foreign matter 130 on the surface 120. The microprocessor 118 facilitates the processing of the images captured by the camera 114 to identify and / or classify the types of the surface 120 and the foreign matter 130 on the surface 120.

[0022] In some embodiments, as shown in Figure 3B, the apparatus 100 further includes a second camera 114A positioned above the camera 114 while the apparatus 100 is inspecting the surface 120. Like the camera 114, the second camera 114A allows the second camera 114A to capture images of the texture within the surface 120 and / or the shadows cast by the foreign matter 130 on the surface 120, and the reflections from the texture within the surface 120 and / or the foreign matter 130 on the surface 120. However, in some embodiments, the second camera 114A is positioned higher than the camera 114 so that, while the apparatus 100 is inspecting the surface 120, it captures images with improved visibility of the shadows compared to the images captured by the camera 114.

[0023] In some embodiments, referring to Figures 2–4B and 6A–6C, the center line 142 of the ray 112 bisects a first ray angle 140A measured in a vertical plane into two equal parts, and bisects a second ray angle 140B measured in a horizontal plane into two equal parts. The ray 112 produced by the light source 106 has a shape defined by the center line 142 of the ray 112 and the shape of the cross-section of the ray 112 along a plane perpendicular to it. The shape of the ray 112 can be any of a variety of shapes, non-limitingly, such as circular (see, e.g., Figure 6A), square (see, e.g., Figure 6B), or rectangular (see, e.g., Figure 6C). Furthermore, the light source 106 can be any of a variety of light sources. In one embodiment, the light source 106 comprises one or more LEDs, such as full-spectrum light-emitting diodes (LEDs). In one embodiment, the light source 106 comprises at least one full-spectrum LED having a rating of 10,000 lumens or more per square foot. In yet another embodiment, the light source 106 comprises at least one dimmable LED.

[0024] In some embodiments, referring to Figures 2-4B and 5A-5C, the camera's line of sight 144 bisects the camera's vertical field of view 116A into two equal parts, and bisects the camera's horizontal field of view 116B into two equal parts. The camera's field of view 113 has a shape defined by the shape of the cross-section of the field of view 113 along a plane perpendicular to the camera's line of sight 144. The shape of the camera's field of view 113 can be any of various shapes, non-limitingly, such as a rectangle (e.g., see Figure 5A), a triangle (e.g., see Figure 5B), or a square (e.g., see Figure 5C). Furthermore, the camera 114 may be a digital camera having an image sensor array.

[0025] The following portion of this paragraph describes an embodiment 2 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figures 3A–4B and 6A–6C. According to embodiment 2, which encompasses embodiment 1 above, the ray 112 also includes a center line 142 and has a first ray angle 140A measured in a third plane 154 that is coplanar with or parallel to the first plane 150. The ray 112 further has a second ray angle 140B measured in a second plane 152.

[0026] The light rays 112, having a first ray angle 140A and a second ray angle 140B, are emitted by the light source 106 to enhance the vertical and horizontal illumination of the texture within the surface 120 and the foreign matter 130 on the surface 120. The shape of the light rays 112 depends on one of the following: the shape of the light source 106, the arrangement of the multiple light-emitting devices of the light source 106, or the configuration of the light filter used in conjunction with the light source 106.

[0027] The following portion of this paragraph describes an embodiment 3 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figure 6C, for example. According to embodiment 3, which encompasses embodiment 2 above, the first ray angle 140A is not equal to the second ray angle 140B.

[0028] Since the first ray angle 140A and the second ray angle 140B are not equal, the efficient use of energy is promoted by allowing the ray 112 to illuminate only the area to be inspected.

[0029] The following portion of this paragraph describes an embodiment 4 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figure 6C, for example. According to embodiment 4, which encompasses embodiment 3 above, the first ray angle 140A is smaller than the second ray angle 140B.

[0030] Since the first ray angle 140A is smaller than the second ray angle 140B, the efficient use of energy is facilitated by allowing the ray 112 to illuminate only the surface 120 that is being inspected.

[0031] The following portion of this paragraph describes an example 5 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figure 6C, for example. According to Example 5, which encompasses Examples 3 or 4 above, the ratio of the first ray angle 140A to the second ray angle 140B is from 0.1 to 0.5.

[0032] The ratio of the first ray angle 140A to the second ray angle 140B is between 0.1 and 0.5, which promotes broad illumination of surface 120 in the horizontal direction parallel to surface 120, and narrow illumination of surface 120 in the vertical direction perpendicular to surface 120.

[0033] The following portion of this paragraph describes an embodiment 6 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figures 3A–4A and 5A–5C. According to embodiment 6, which encompasses any one of embodiments 1 to 5 above, the camera 114 also has a first field of view 116A, which includes a line of sight 144 and is measured in a third plane 154 that is coplanar with or parallel to the first plane 150. The camera 114 further has a second field of view 116B, which is measured in a second plane 152.

[0034] The camera 114, having a first field of view 116A and a second field of view 116B, facilitates the acquisition of images of the surface 120 and foreign objects 130 on the surface 120. The shape of the field of view 113 of the camera 114, and accordingly the first field of view 116A and the second field of view 116B, depend on the shape and size of the image sensor array of the camera 114.

[0035] The following portion of this paragraph describes an example 7 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 5A. According to Example 7, which encompasses Example 6 above, the first field of view 116A is not equal to the second field of view 116B.

[0036] Since the first field of view 116A and the second field of view 116B are not equal, it facilitates the acquisition of images of only the area to be inspected. This promotes efficient inspection by excluding non-target areas from the image. This avoids unnecessary analysis of non-target areas that would occupy valuable bandwidth and processing power.

[0037] The following portion of this paragraph describes an embodiment 8 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 5A, for example. According to embodiment 8, which encompasses embodiment 7 above, the first field of view 116A is smaller than the second field of view 116B.

[0038] Since the first field of view 116A is smaller than the second field of view 116B, it facilitates the acquisition of an image of only a selected portion of the surface 120. This promotes efficient inspection of the surface 120 to confirm the type of surface 120 and / or foreign matter 130 on the surface 120.

[0039] The following portion of this paragraph describes an example 9 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figure 5A, for example. According to Example 9, which encompasses Examples 7 or 8 above, the ratio of the first field of view 116A to the second field of view 116B is from 0.1 to 0.5.

[0040] The ratio of the first field of view 116A to the second field of view 116B is between 0.1 and 0.5, which facilitates the acquisition of images of a large portion of the surface 120 in the horizontal direction and a small portion of environmental objects perpendicular to the surface 120.

[0041] The following portion of this paragraph describes an embodiment 10 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, to Figures 2-4B. According to embodiment 10, which encompasses any one of embodiments 1 to 9 described above, the apparatus 100 further comprises a operable electric chassis 102. A light source 106 and a camera 114 are coupled to the operable electric chassis 102.

[0042] The operable electric chassis 102 enables the motorized movement of the light source 106 and camera 114 relative to the surface 120. Thus, the operable electric chassis 102 facilitates remote inspection of the surface 120 without requiring a technician to be near the surface 120 during inspection. Furthermore, because the operable electric chassis 102 is smaller than the technician, it enables inspection of surfaces that are difficult for the technician to access. In addition, the operable electric chassis 102 helps to position the light source 106 and camera 114 closer to the surface 120 for more efficient and accurate confirmation of the surface 120 and / or the type of foreign matter 130 on the surface 120.

[0043] The following portion of this paragraph describes an embodiment 11 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 3A, for example. According to embodiment 11, which encompasses embodiment 10 described above, the operable electric chassis 102 comprises a power supply 103, a motor 105, and a control mechanism 107. A microprocessor 118 is coupled to the power supply 103, the motor 105, and the control mechanism 107 in a communicative manner.

[0044] The power supply 103, motor 105, and control mechanism 107 of the controllable electric chassis 102 enable remote control of the controllable electric chassis 102. The microprocessor is coupled to the power supply 103, motor 105, and control mechanism 107 for communication purposes.

[0045] The following portion of this paragraph describes an embodiment 12 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 3A. According to embodiment 12, which encompasses embodiment 11 described above, the operable electric chassis 102 further comprises wheels 104 configured to be operably coupled to a steering mechanism 107 and to rotate along a surface 120.

[0046] The wheels 104 facilitate the movement of the operable electric chassis 102 along the plane 110 defined by the surface 120 of the part 101. Furthermore, since the wheels 104 are operably coupled to the steering mechanism 107, the operable electric chassis 102 can be moved in any of several directions relative to the surface 120 while the surface 120 is being inspected by the device 100. The wheels 104 further facilitate the positioning of the light source 106 and camera 114 near the surface 120.

[0047] The following portion of this paragraph describes an embodiment 13 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 3A. According to embodiment 13, which encompasses any one of embodiments 1 to 12 above, the apparatus 100 further comprises a light detection and ranging (LIDAR) system 131 communicatively coupled to a microprocessor 118.

[0048] The LIDAR system 131 assists the device 100 in navigating the environment in which the surface 120 forms the part. The LIDAR system 131 enables the identification of environmental features within the environment. This helps the device 100 to avoid environmental areas not to be inspected, avoid collisions with environmental features, and identify the inspection path along which the device 100 moves when inspecting the surface 120. Furthermore, the LIDAR system 131 enables the mapping and localization of foreign objects 130 identified by the device 100.

[0049] The following portion of this paragraph describes an embodiment 14 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, for example, Figures 2-4B and Figures 6A-8B. According to embodiment 14, which encompasses any one of the above embodiments 1 to 13, the light source 106 comprises a full-spectrum light-emitting diode (LED).

[0050] Since the light source 106 is a full-spectrum LED, it is useful for illuminating the surface 120 and the foreign matter 130 on the surface with light that covers the entire visible spectrum. By illuminating the surface 120 and the foreign matter 130 with light that covers the entire visible spectrum, it is possible to illuminate surfaces and foreign matter 130 made of various materials, and thus an accurate spatial representation of the surface 120, the foreign matter 130, and the corresponding environment can be obtained.

[0051] The following portion of this paragraph describes an embodiment 15 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 1 and, in particular, Figure 7, for example. According to embodiment 15, which encompasses any one of embodiments 1 to 14 described above, the apparatus 100 further comprises an end effector 109. A light source 106 and a camera 114 are coupled to the end effector 109.

[0052] The end effector 109 enables the automated movement of the light source 106 and camera 114 relative to the surface 120 without contact with the surface 120. In some embodiments, the end effector 109 also enables inspection of the surface 120 when the surface 120 would not be suitable for supporting the device 100 on it. According to some embodiments, the end effector 109 is coupled to a robot 111, which facilitates the movement of the end effector 109 with multiple degrees of freedom.

[0053] The following portion of this paragraph describes an embodiment 16 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 9 and, in particular, to Figures 2-4C and 7. According to embodiment 16, which encompasses embodiment 1 above, the method 200 for inspecting a surface 120 using apparatus 100 includes the step (block 202) of using a camera 114 to capture an image of at least a portion of the pixels of the surface 120 while illuminating the surface 120 with a ray 112. The acute angle between the center line 142 of the ray 112 and the surface 120 is between 0 and 30 degrees when measured in a plane perpendicular to the surface 120 and containing the center line 142. At least one grayscale value of the pixels differs from at least one other grayscale value of the pixels. Thereafter, the pixels of the image generate a pixel pattern. Method 200 also includes the step (block 204) of comparing the pixel pattern of an image with an archived pixel pattern to determine whether the pixel pattern of the image matches one of the archived pixel patterns, wherein each of the archived pixel patterns corresponds to one of several different types of surfaces.

[0054] Method 200 allows for verification of the surface type 120 of part 101. Illuminating surface 120 with a ray 112 helps to create shadows from surface features 122 (e.g., texture) of surface 120. The acute angle between the center line 142 of the ray 112 and surface 120 is between 0 and 30 degrees, which helps ensure that shadows are reliably created even from small surface features. At least one grayscale value of a pixel differs from at least one other grayscale value of a pixel, indicating the presence of a shadow-casting surface feature in the image. By comparing the resulting image's pixel pattern with an archived pixel pattern and determining whether the image's pixel pattern matches one of the archived pixel patterns, it can be confirmed that surface type 120 corresponds to the surface type of the matching archived pixel pattern.

[0055] Each of the archived pixel patterns is associated with a specific type of surface. The surface type is one of the material of the part 101 defining the surface 120 and / or the state or surface finish of the surface 120. The archived pixel patterns can be generated by taking images of the surface of a standard material having various surface states or finishes under lighting conditions designed to match those generated during the execution of Method 200, prior to the execution of Method 200. For example, a part made of fiber-reinforced polymer material will produce a specific pattern of shadow and therefore a specific pixel pattern. This is different from the specific pattern of shadow produced from a part made of metallic material and is different from the corresponding specific pixel pattern of a part made of metallic material. As shown in Figure 4C, in another embodiment, part 101 may be made of the same material, but the surface finish applied to the surface 120 of part 101 may be different (for example, the surface 120 of part 101 may have a first portion having a first surface finish 122A, a second portion having a second surface finish 122B that is rougher than the first surface finish 122A, and a third portion having a third surface finish 122C that is smoother than the first surface finish 122A). In one embodiment, the first surface finish 122A may be a properly finished surface, the second surface finish 122B may be an under-finished surface, and the third surface finish 122C may be an over-finished surface. Thus, method 200 may be performed to determine whether the surface 120 of part 101 is improperly finished by comparing various pixel patterns of an image with an archived pixel pattern.

[0056] The following portion of this paragraph describes an example 17 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figure 9 and, in particular, to Figures 3A and 3B. According to Example 17, which encompasses Example 16 above, the surface 120 is illuminated by a ray 112, and an image of the surface 120 is captured when the origin A of the ray 112 is located between 1 cm and 200 cm away from the surface 120.

[0057] By illuminating surface 120 with a ray 112 and capturing an image of surface 120 when the origin A of the ray 112 is 1 cm to 200 cm away from surface 120 (i.e., when the height H1 is 1 cm to 200 cm above surface 120), it is easy to determine that shadows are formed even from small surface features. Since the origin A of the ray 112 is close to surface 120, shadows are formed from surface features 122 that protrude from surface 120 and surface features 122 that are recessed or indented within surface 120. Therefore, method 200 makes it possible to identify the types of surfaces that form protrusion patterns, the types of surfaces that form indentation patterns, or the types of surfaces that form both protrusion and indentation patterns.

[0058] As shown in Figure 3A, when the acute angle between the center line 142 of ray 112 and the surface 120 is zero, the height H1 of the origin A of ray 112 is equal to the second height H2 of the center line 142 of ray 112 at position B downstream from the origin A. However, as shown in Figure 3B, when the acute angle between the center line 142 of ray 112 and the surface 120 is greater than zero, the height H1 of the origin A of ray 112 is greater than the second height H2 of the center line 142 of ray 112 at position B.

[0059] The following portion of this paragraph describes an embodiment 18 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 2-4D and Figures 7-8C. According to embodiment 18, which encompasses the subject matter of embodiment 1 above, a method 300 for inspecting a surface 120 for foreign matter 130 using apparatus 100 includes the step (block 302) of illuminating the surface 120 with a ray 112 and capturing an image containing pixels using a camera 114. The acute angle between the center line 142 of the ray 112 and the surface 120 is measured in a plane perpendicular to the surface 120 and containing the center line 142, and ranges from 0 to 30 degrees. Method 300 also includes the step (block 304) of designating an object 130A that protrudes from surface 120 and has a contact area 131A with surface 120 as one of the foreign objects 130, such that the image includes at least one of a first subset of pixels corresponding to a first continuous region 132 on surface 120 or a second subset of pixels corresponding to a second continuous region 134 on surface 136 of object 130A. The first continuous region 132 on surface 120 is continuous with object 130A. The first continuous region 132 on surface 120 receives less energy from the rays 112 than a first circumferentially closed portion 133 of surface 120. The first circumferentially closed portion 133 of surface 120 completely borders the first continuous region 132 on surface 120 and the contact area 131A of object 130A with surface 120 by drawing a boundary line around it. The second continuous region 134 on the surface 136 of object 130A reflects more energy from the light ray 112 than the second circumferentially closed portion 138 of the surface 136 of object 130A. The second circumferentially closed portion 138 of the surface 136 of object 130A completely borders the second continuous region 134 on the surface 136 of object 130A by drawing a boundary line around it.

[0060] Method 300 enables inspection of the surface 120 of part 101 for foreign matter 130 using a ray 112 of light source 106 and an image captured by camera 114 to identify and identify foreign matter 130 on the surface 120. The acute angle between the center line 142 of the ray 112 and the surface 120 is between 0 and 30 degrees, which helps ensure that shadows are cast from the foreign matter 130 on the surface 120 and / or that light is reflected from the foreign matter 130 on the surface 120. The pixels of a first subset, when included in the image, provide a digital representation of the shadow cast from the foreign matter 130 on the surface 120. The pixels of a second subset, when included in the image, provide a digital representation of the light reflected from the foreign matter 130. Thus, when the image contains at least one of the pixels of the first subset or the pixels of the second subset, the presence of an object 130A on the surface 120 is identified and designated as foreign matter 130.

[0061] The following portion of this paragraph describes 19 embodiments of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B, and in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 19, which encompasses Example 18 above, when an object 130A protruding from a surface 120 is designated as one of the foreign objects 130, Method 300 further includes the steps of: comparing the image with an archived image of a standard object (block 306); associating the object 130A with a specific standard object when at least one of the pixels of a first subset of the image or the pixels of a second subset matches the pixels of one subset of the archived image corresponding to a specific standard object (block 308); and associating the object 130A with a non-standard object that is initially different from each other and is not one of the standard objects when neither the pixels of the first subset of the image nor the pixels of the second subset match the pixels of any subset of the archived image of a standard object (block 310).

[0062] By comparing the image with archived images of a standard object, it becomes possible to associate object 130A with either a standard or non-standard object. Standard archived images can be generated by imaging a standard object (e.g., a hammer, nail, staple, nut, washer, O-ring, etc.) under lighting conditions designed to match those generated during the execution of method 300, prior to the execution of method 300.

[0063] The following portion of this paragraph describes an embodiment 20 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 2-4D and Figures 7-8C. According to embodiment 20, which encompasses embodiment 19 above, when object 130A is initially associated with a non-standard object, method 300 further includes the steps of comparing the image with an archived image of the non-standard object (block 312), and designating one particular non-standard object as one of the further standard objects when at least one of the pixels of a first subset of the image or the pixels of a second subset matches the pixels of one subset of archived images corresponding to one particular non-standard object, and associating object 130A with one of the further standard objects (block 314).

[0064] By comparing the image with archived images of non-standard objects and designating object 130A as one of the standard objects, the machine learning function can extend the archived images of standard objects. This improves the accuracy and efficiency of method 300 as it is run repeatedly.

[0065] The following portion of this paragraph describes an embodiment 21 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 2-4D and Figures 7-8C. According to embodiment 21, which encompasses embodiment 20 above, method 300 further includes the step (block 316) of using a fluid to verify whether object 130A can be removed from surface 120 when object 130A is associated with a non-standard object.

[0066] After object 130A is associated with a non-standard object, it can be confirmed that object 130A is foreign debris and not a defect in surface 120 by verifying whether object 130A is removable from surface 120. The fluid can be any of a variety of fluids, such as water, cleaning fluid, or air. The process of attempting to remove object 130A can be any of a variety of processes, such as directing a fluid flow from a high-pressure fluid source towards object 130A. In some embodiments, the apparatus 100 includes a feature that can direct the fluid towards object 130A. In other embodiments, a separate tool from the apparatus 100 is used to direct the fluid towards object 130A. Verification of whether object 130A has been removed can be achieved by performing method 300. Method 300 takes a second image of surface 120 at the mapped location of object 130A and determines whether pixels from a first subset or a second subset are included in the second image. The mapped location of object 130A can be determined using the LIDAR system 131.

[0067] The following portion of this paragraph describes an example 22 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 22, which encompasses Example 21 above, Method 300 further includes the step (block 318) of classifying object 130A as a defect of surface 120 when object 130A is associated with a non-standard object and object 130A cannot be removed from surface 120 using a fluid.

[0068] By classifying object 130A as a defect on surface 120, it can be confirmed that object 130A is not foreign debris, providing an opportunity to repair the defect on part 101 or to adjust manufacturing parameters during future part manufacturing.

[0069] The following portion of this paragraph describes an example 23 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 23, which encompasses Example 21 above, Method 300 further includes the step (block 320) of classifying object 130A as foreign debris when object 130A is associated with a non-standard object and when object 130A is removable from surface 120 using a fluid.

[0070] Classifying object 130A as foreign debris helps to confirm that object 130A was removed from part 101 and is not a defect in part 101.

[0071] The following portion of this paragraph describes an example 24 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B, and in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 24, which encompasses any one of Examples 18 to 23 above, the pixels of a first subset have the maximum grayscale value. The pixels of a second subset have the minimum grayscale value. The minimum grayscale value of the pixels of the second subset is greater than the maximum grayscale value of the pixels of the first subset.

[0072] The minimum grayscale value of the pixels in the second subset is greater than the maximum grayscale value of the pixels in the first subset, allowing the first continuous region 132 to be associated with the shadow cast by object 130A, and the second continuous region 134 to be associated with the reflection of light from object 130A. In the case of a black and white image, the higher the grayscale value of the pixels in the image, the brighter the pixels. Conversely, the lower the grayscale value of the pixels in the image, the darker the pixels.

[0073] The following portion of this paragraph describes an example 25 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B, and in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 25, which encompasses Example 24 above, the maximum grayscale value is from 0 to 100. The minimum grayscale value is from 200 to 255.

[0074] Since the maximum grayscale value is from 0 to 100, the first continuous region 132 can be accurately associated with shadows. Since the minimum grayscale value is from 200 to 255, the second continuous region 134 can be accurately associated with light reflections. When used herein, grayscale values ​​are used to represent the darkness and brightness of pixels in an image, ranging from 0, where the pixel is darkest, to 255, where the pixel is brightest.

[0075] The following portion of this paragraph describes an example 26 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B, and in particular, for example, Figures 2-4D and Figures 7-8C. According to Example 26, which encompasses Example 25 described above, the maximum grayscale value is 50. The minimum grayscale value is 238.

[0076] The maximum grayscale value is 50, which allows the first continuous region 132 to be associated more accurately with shadows. The minimum grayscale value is 238, which allows the second continuous region 134 to be associated more accurately with light reflections.

[0077] The following portion of this paragraph describes an embodiment 27 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 8A to 8C. According to embodiment 27, which encompasses any one of the above embodiments 18 to 26, method 300 further includes the steps of: moving the apparatus 100 around a first continuous region 132 of the surface 120 while illuminating the surface 120 with the light rays 112 of the apparatus 100 when the image contains a first subset of pixels (block 322); using the camera 114 of the apparatus 100 to capture a supplemental image of the first continuous region 132 on the surface 120 as the apparatus 100 moves around the first continuous region 132 on the surface 120 (block 324); and comparing the supplemental image of the first continuous region 132 on the surface 120 with each other and with an image having the first subset of pixels (block 326). Method 300 further includes the steps of: moving the device 100 around a second continuous region 134 on the surface 136 of object 130A while illuminating the surface 120 with the light rays 112 of the device 100 when the image contains pixels of a second subset (block 328); using the camera 114 of the device 100 to capture a supplemental image of the second continuous region 134 on the surface 136 of object 130A as the device 100 moves around the second continuous region 134 on the surface 136 of object 130A (block 330); and comparing the supplemental image of the second continuous region 134 on the surface 136 of object 130A with each other and with images containing pixels of the second subset (block 332).

[0078] Orbiting the device 100 around the first continuous region 132, capturing a supplementary image of the first continuous region 132, and comparing the supplementary images of the first continuous region 132 with each other and with images having pixels of the first subset helps to confirm that the image contains pixels of the first subset. When the image contains pixels of the first subset, it is expected that the supplementary images will contain the first continuous region 132 having pixels similar to those of the first subset. When each of the supplementary images contains the first continuous region 132 having pixels similar to those of the first subset, the determination that the initial image contains pixels of the first subset may be considered accurate. However, when one or more of the supplementary images contain the first continuous region 132 having pixels that are not similar to those of the first subset, the determination that the image contains pixels of the first subset may be considered inaccurate.

[0079] Orbiting the device 100 around the second continuous region 134, capturing a supplementary image of the second continuous region 134, and comparing the supplementary images of the second continuous region 134 with each other and with images having pixels of the second subset helps to confirm that the image contains pixels of the second subset. When the image contains pixels of the second subset, it is expected that the supplementary images will contain the second continuous region 134 having pixels similar to those of the second subset. When each of the supplementary images contains the second continuous region 134 having pixels similar to those of the second subset, the determination that the image contains pixels of the second subset may be considered accurate. However, when one or more of the supplementary images contain the second continuous region 134 having pixels that are not similar to those of the second subset, the determination that the image contains pixels of the second subset may be considered inaccurate.

[0080] The following portion of this paragraph describes an embodiment 28 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 3A and 8A-8C. According to embodiment 28, which encompasses embodiment 27 above, either the step of orbiting the device 100 around a first continuous region 132 on the surface 120 (block 322) or the step of orbiting the device 100 around a second continuous region 134 on the surface 120 (block 328) includes using a LiDAR system 131 to detect the position of the device 100 relative to the surface 120 (block 334).

[0081] By using the LIDAR system 131 to detect the position of the device 100 relative to the surface 120, the device 100 can orbit around the first continuous region 132 and / or the second continuous region 134 without colliding with the object 130A.

[0082] The following portion of this paragraph describes an embodiment 29 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 8A to 8C. According to embodiment 29, which encompasses embodiment 27 above, the apparatus 100 captures an image having the first subset of pixels when the image includes a first subset of pixels and the camera 114 is at a first known distance D from the first continuous region 132 on the surface 120, and the apparatus 100 circles the first continuous region 132 on the surface 120. Thereafter, the camera 114 remains at a first known distance D from the first continuous region 132 on the surface 120. Thereafter, the camera 114 captures a supplemental image of the first continuous region 132 on the surface 120. When the image contains a second subset of pixels and the camera 114 is at a second known distance D1 from the second continuous region 134 on the surface 136 of object 130A, the apparatus 100 captures an image with the second subset of pixels, and the apparatus 100 orbits the second continuous region 134 on the surface 136 of object 130A. Thereafter, the camera 114 remains at a second known distance D1 from the second continuous region 134 on the surface 136 of object 130A. Thereafter, the camera 114 captures a supplemental image of the second continuous region 134 on the surface 136 of object 130A.

[0083] By orbiting the device 100 around the first continuous region 132 so that camera 114 acquires a supplemental image of the first continuous region 132 when camera 114 is at a first known distance D from the first continuous region 132, conditions are made to facilitate accurate comparison between the first continuous region 132 in each of the supplemental images having a first subset of pixels and the first continuous region 132 in the image. By orbiting the device 100 around the first continuous region 134 so that camera 114 acquires a supplemental image of the second continuous region 134 when camera 114 is at a second known distance D1 from the second continuous region 134, conditions are made to facilitate accurate comparison between the second continuous region 134 in each of the supplemental images having a second subset of pixels and the second continuous region 134 in the image.

[0084] The following portion of this paragraph describes an embodiment 30 of the subject matter disclosed herein, not in an illustrative or limiting manner, but generally with reference to Figures 10A and 10B and, in particular, for example, Figures 3A and 8A-8C. According to embodiment 30, which encompasses embodiment 29 above, either the step of orbiting the device 100 around a first continuous region 132 on the surface 120 (block 322) or the step of orbiting the device 100 around a second continuous region 134 on the surface 120 (block 328) includes using a LiDAR system 131 to detect the position of the device 100 relative to the surface 120 (block 334). Method 300 further includes the steps of using the LIDAR system 131 to determine a first known distance D when the image includes a first subset of pixels (block 336), and using the LIDAR system 131 to determine a second known distance D1 when the image includes a second subset of pixels (block 338).

[0085] By using the LIDAR system 131 to detect the position of the device 100 relative to the surface 120 and to determine a first known distance D, the device 100 can orbit around the first continuous region 132 without colliding with the object 130A. Similarly, by using the LIDAR system 131 to detect the position of the device 100 relative to the surface 120 and to determine a second known distance D1, the device 100 can orbit around the second continuous region 134 without colliding with the object 130A.

[0086] Various embodiments of the (one or more) apparatuses and (one or more) methods disclosed herein include a variety of components, features, and functions. It should be understood that various embodiments of the apparatuses and methods disclosed herein may include, in any combination, any components, features, and functions of any other embodiment of the apparatuses and methods disclosed herein.

[0087] Those skilled in the art who benefit from the teachings presented in the preceding description and accompanying drawings will likely be able to conceive of many variations of the embodiments described herein.

[0088] Furthermore, the present invention includes embodiments as defined below. Article 1. A device (100) for inspecting a surface (120), A light source (106) configured to generate a ray (112) having a center line (142), A camera (114) having a line of sight (144), and The camera (114) is connected to a microprocessor (118) in a communication manner, When the aforementioned light ray (112) is generated by the aforementioned light source (106), The center line (142) of the ray (112) coincides with the line of sight (144) of the camera (114) when viewed in a direction perpendicular to the first plane (150) which includes either the center line (142) of the ray (112) or the line of sight (144) of the camera (114). Apparatus (100) wherein the center line (142) of the ray (112) is perpendicular to the first plane (150) and is parallel to the line of sight (144) of the camera (114) when viewed in a direction perpendicular to the second plane (152) which includes the center line (142) of the ray (112) and the line of sight (144) of the camera (114). Article 2. The aforementioned ray (112) also, A first ray angle (140A) measured in a third plane (154) that includes the center line (142) and is coplanar with or parallel to the first plane (150), and The apparatus (100) according to Clause 1, also having a second ray angle (140B) measured in the second plane (152). Article 3. The apparatus (100) described in Clause 2, wherein the first ray angle (140A) is not equal to the second ray angle (140B). Article 4. The apparatus (100) described in Clause 3, wherein the first ray angle (140A) is smaller than the second ray angle (140B). Article 5. The apparatus (100) described in Clause 3, wherein the ratio of the first ray angle (140A) to the second ray angle (140B) is between 0.1 and 0.5. Article 6. The aforementioned camera (114) also, A first field of view (116A) measured in a third plane (154) that is coplanar with or parallel to the first plane (150), including the line of sight (144), and The apparatus (100) according to any one of the clauses 1 to 5, also having a second field of view (116B) measured within the second plane (152). Article 7. The apparatus (100) described in Clause 6, wherein the first field of view (116A) is not equal to the second field of view (116B). Article 8. The apparatus (100) described in Clause 7, wherein the first field of view (116A) is smaller than the second field of view (116B). Article 9. The apparatus (100) according to Clause 7 or 8, wherein the ratio of the first field of view (116A) to the second field of view (116B) is 0.1 to 0.5. Article 10. The apparatus (100) according to any one of the clauses 1 to 9, further comprising a controllable electric chassis (102), wherein the light source (106) and the camera (114) are coupled to the controllable electric chassis (102). Article 11. The operable electric chassis (102) is equipped with a power supply (103), a motor (105), and a control mechanism (107). The apparatus (100) according to clause 10, wherein the microprocessor (118) is communicatively coupled to the power supply (103), the motor (105), and the control mechanism (107). Article 12. The apparatus (100) according to Clause 11, wherein the operable electric chassis (102) further comprises wheels (104) configured to rotate along the surface (120) and operably coupled to the steering mechanism (107). Article 13. The apparatus (100) according to any one of the clauses 1 to 12, further comprising a light detection and ranging (LIDAR) system (131) communicatively coupled to the microprocessor (118). Article 14. The light source (106) is the apparatus (100) described in any one of the clauses 1 to 13, including a full-spectrum light-emitting diode (LED). Article 15. The apparatus (100) according to any one of the clauses 1 to 14, further comprising an end effector (109), wherein the light source (106) and the camera (114) are coupled to the end effector (109). Article 16. A method (200) for inspecting the surface (120) using the apparatus (100) described in Clause 1, The step of capturing an image including pixels of at least a portion of the surface (120) using the camera (114) while illuminating the surface (120) with the light ray (112), When the acute angle between the center line (142) of the ray (112) and the surface (120) is measured in a plane perpendicular to the surface (120) and containing the center line (142), it is between 0 and 30 degrees. The grayscale value of at least one of the pixels differs from the grayscale value of at least one other of the pixels, and the pixels of the image generate a pixel pattern, step, and A method (200) comprising the step of comparing the pixel pattern of the image with one of the archived pixel patterns in order to determine whether the pixel pattern of the image matches one of the archived pixel patterns, wherein each of the archived pixel patterns corresponds to one of a plurality of different types of surfaces. Article 17. The method (200) of clause 16, wherein the surface (120) is illuminated with the light ray (112), and when the origin (A) of the light ray (112) is located at a distance of 1 cm to 200 cm from the surface (120), the image of the surface (120) is captured. Article 18. A method (300) for inspecting the surface (120) for foreign matter (130) using the apparatus (100) described in Clause 1, A step of capturing an image including pixels using the camera (114) while illuminating the surface (120) with the light ray (112), wherein the acute angle between the center line (142) of the light ray (112) and the surface (120) is measured in a plane perpendicular to the surface (120) and including the center line (142), and is between 0 and 30 degrees, and The aforementioned image is, A first subset of pixels corresponding to a first continuous region (132) on the surface (120), wherein the first continuous region (132) on the surface (120) is continuous with the object (130A), the first continuous region (132) on the surface (120) receives less energy from the light ray (112) than the first circumferentially closed portion (133) of the surface (120), and the first circumferentially closed portion (133) of the surface (120) completely demarcates the first continuous region (132) on the surface (120) and the contact area (131A) of the object (130A) with the surface (120) by drawing a boundary line around it, or A second subset of pixels corresponding to a second continuous region (134) on the surface (136) of the object (130A), wherein the second continuous region (134) on the surface (136) of the object (130A) reflects more energy from the light ray (112) than the second circumferentially closed portion (138) of the surface (136) of the object (130A), and the second circumferentially closed portion (138) of the surface (136) of the object (130A) includes at least one of the pixels of the second subset that completely borders the second continuous region (134) on the surface (136) of the object (130A) by drawing a boundary line around it. A method (300) comprising the step of designating an object (130A) that protrudes from the surface (120) and has a contact area (131A) with the surface (120) as one of the foreign objects (130). Article 19. When the object (130A) protruding from the surface (120) is designated as one of the foreign matter (130), the method (300) is: The step of comparing the aforementioned image with an archived image of a standard object, The steps of associating the object (130A) with the particular one of the standard objects when at least one of the pixels of the first subset or the pixels of the second subset of the image matches a pixel of one subset of the archived image that corresponds to a particular one of the standard objects, and The method according to Clause 18 (300), further comprising the step of associating the object (130A) with non-standard objects that are different from each other and different from any of the standard objects, when none of the pixels of the first subset of the image or the pixels of the second subset of the image match any of the pixels of any subset of the archived image of the standard object. Article 20. When the object (130A) was initially associated with the non-standard object, The steps include comparing the aforementioned image with archived images of non-standard objects, and The method according to Clause 19 (300), further comprising the step of designating the particular non-standard object as one of the standard objects and associating the object (130A) with the one of the standard objects when at least one of the pixels of the first subset of the image or the pixels of the second subset matches a pixel of one subset of the archived image corresponding to one of the particular non-standard objects. Article 21. The method according to clause 20 (300), further comprising the step of using a fluid to verify whether the object (130A) can be removed from the surface (120) when the object (130A) is associated with the non-standard object. Article 22. The method according to Clause 21 (300), further comprising the step of classifying the object (130A) as a defect of the surface (120) when the object (130A) is associated with the non-standard object and the object (130A) is not removable from the surface (120) using the fluid. Article 23. The method according to Clause 21 (300), further comprising the step of classifying the object (130A) as foreign debris when the object (130A) is associated with the non-standard object and the object (130A) is removable from the surface (120) using the fluid. Article 24. The pixels of the first subset have the maximum grayscale value, The pixels of the second subset have a minimum grayscale value, The method according to any one of the clauses 18 to 23 (300), wherein the minimum grayscale value of the pixels in the second subset is greater than the maximum grayscale value of the pixels in the first subset. Article 25. The aforementioned maximum grayscale value ranges from 0 to 100. The method according to Clause 24 (300), wherein the minimum grayscale value is 200 to 255. Article 26. The aforementioned maximum grayscale value is 50. The minimum grayscale value is 238, according to the method described in Clause 25 (300). Article 27. When the image includes the pixels of the first subset, The step of rotating the device (100) around the first continuous region (132) of the surface (120) while illuminating the surface (120) with the light ray (112) of the device (100), The steps include: when the device (100) is moving around the first continuous region (132) on the surface (120), using the camera (114) of the device (100) to capture a supplementary image of the first continuous region (132) on the surface (120); and The steps include comparing the supplementary image of the first continuous region (132) on the surface (120) with each other and with the image having pixels of the first subset, and When the aforementioned image includes pixels of the second subset, The step of rotating the device (100) around the second continuous region (134) on the surface (136) of the object (130A) while illuminating the surface (120) with the light ray (112) of the device (100), The steps include: when the device (100) is moving around the second continuous region (134) on the surface (136) of the object (130A), the camera (114) of the device (100) is used to capture a supplementary image of the second continuous region (134) on the surface (136) of the object (130A); and Method (300) further comprising the step of comparing the supplementary image of the second continuous region (134) on the surface (136) of the object (130A) with the image having pixels of each other and of the second subset. Article 28. The method(300) of Clause 27, wherein either step of moving the device(100) around the first continuous region(132) on the surface(120) or step of moving the device(100) around the second continuous region(134) on the surface(136) of the object(130A) includes using a light detection and ranging (LIDAR) system(131) to detect the position of the device(100) relative to the surface(120). Article 29. When the image includes pixels of the first subset and the camera (114) is located at a first known distance (D) from the first continuous region (132) on the surface (120), The apparatus (100) captures the image having the first subset of pixels, The apparatus (100) orbits the first continuous region (132) on the surface (120), the camera (114) remains at a distance of the first known distance (D) from the first continuous region (132) on the surface (120), and the camera (114) captures the supplementary image of the first continuous region (132) on the surface (120). When the image includes the pixels of the second subset, and the camera (114) is located at a second known distance (D1) from the second continuous region (134) on the surface (136) of the object (130A), The apparatus (100) captures the image having the second subset of pixels, The method (300) according to Clause 27, wherein the apparatus (100) orbits the second continuous region (134) on the surface (136) of the object (130A), the camera (114) remains at a second known distance (D1) away from the second continuous region (134) on the surface (136) of the object (130A), and the camera (114) captures a supplementary image of the second continuous region (134) on the surface (136) of the object (130A). Article 30. Either the step of orbiting the device (100) around the first continuous region (132) on the surface (120) or the step of orbiting the device (100) around the second continuous region (134) on the surface (136) of the object (130A) includes using a light detection and ranging (LIDAR) system (131) to detect the position of the device (100) relative to the surface (120), The above method (300) is, The steps include: determining the first known distance (D) using the LIDAR system (131) when the image includes pixels of the first subset, and The method according to clause 29 (300), further comprising the step of using the LIDAR system (131) to determine the second known distance (D1) when the image includes pixels of the second subset.

[0089] Therefore, it should be understood that this disclosure is not limited to the specific embodiments illustrated, and that modifications and other embodiments are intended to be included in the appended claims. Furthermore, while the descriptions in the prior specification and the associated drawings illustrate examples of the subject matter of the invention disclosed herein in light of specific exemplary combinations of elements and / or functions, it should be understood that various combinations of elements and / or functions can be provided by alternative embodiments without departing from the scope of the appended claims. Accordingly, the reference numerals enclosed in parentheses in the appended claims are provided for illustrative purposes only and are not intended to limit the scope of the subject matter of the claimed invention to the specific embodiments provided herein.

Claims

1. An apparatus (100) for inspecting a surface (120), comprising: a light source (106) configured to generate a light beam (112) having a centerline (142); a camera (114) having line of sight (144); and a microprocessor (118) communicatively coupled to the camera (114); When the light beam (112) is generated by the light source (106), the center line (142) of the light beam (112) coincides with the line of sight (144) of the camera (114) when viewed in a direction perpendicular to a first plane (150) that includes one of the center line (142) of the light beam (112) or the line of sight (144) of the camera (114); The apparatus (100) has a center line (142) of the light beam (112) that is perpendicular to the first plane (150) and parallel to the line of sight (144) of the camera (114) when viewed in a direction perpendicular to a second plane (152) that includes the center line (142) of the light beam (112) and the line of sight (144) of the camera (114).

2. The light beam (112) also a first ray angle (140A) measured in a third plane (154) that includes the centerline (142) and is coplanar or parallel to the first plane (150); and The apparatus (100) of claim 1, also having a second ray angle (140B) measured in the second plane (152).

3. 3. The apparatus (100) of claim 2, wherein the first ray angle (140A) is not equal to the second ray angle (140B).

4. The device (100) of claim 3, wherein the first ray angle (140A) is smaller than the second ray angle (140B).

5. The camera (114) also a first angle of view (116A) measured in a third plane (154) that includes the line of sight (144) and is coplanar or parallel to the first plane (150); and The apparatus (100) of any one of claims 1 to 4, also having a second angle of view (116B) measured in the second plane (152).

6. The apparatus (100) of claim 5, wherein the first angle of view (116A) is not equal to the second angle of view (116B).

7. The device (100) described in claim 6, wherein the first angle of view (116A) is smaller than the second angle of view (116B).

8. 10. The apparatus (100) of claim 1, further comprising a steerable powered chassis (102), wherein the light source (106) and the camera (114) are coupled to the steerable powered chassis (102).

9. The steerable electric chassis (102) comprises a power source (103), a motor (105), and a steering mechanism (107); 9. The apparatus (100) of claim 8, wherein the microprocessor (118) is communicatively coupled to the power source (103), the motor (105), and the steering mechanism (107).

10. 9. The apparatus (100) of claim 8, wherein the steerable powered chassis (102) further comprises wheels (104) operatively coupled to the steering mechanism (107) and configured to rotate along the surface (120).

11. The apparatus (100) of claim 1, further comprising a light detection and ranging (LIDAR) system (131) communicatively coupled to the microprocessor (118).

12. The apparatus (100) of claim 1, wherein the light source (106) comprises a full-spectrum light-emitting diode (LED).

13. The apparatus (100) of claim 1, further comprising an end effector (109), wherein the light source (106) and the camera (114) are coupled to the end effector (109).

14. 10. A method (300) of inspecting the surface (120) for foreign matter (130) using the apparatus (100) of claim 1, comprising: capturing an image comprising pixels using the camera (114) while illuminating the surface (120) with the light beam (112), wherein an acute angle between the center line (142) of the light beam (112) and the surface (120) is between 0 and 30 degrees, measured in a plane perpendicular to the surface (120) and containing the center line (142); and The image is a first subset of pixels corresponding to a first contiguous region (132) on the surface (120), the first contiguous region (132) on the surface (120) being contiguous with an object (130A), the first contiguous region (132) on the surface (120) receiving less energy from the light ray (112) than a first circumferentially closed portion (133) of the surface (120), the first circumferentially closed portion (133) of the surface (120) completely bounding the first contiguous region (132) on the surface (120) and a contact area (131A) of the object (130A) with the surface (120); or a second subset of pixels corresponding to a second contiguous region on the surface of the object, the second contiguous region reflecting more energy from the light ray than a second circumferentially closed portion of the surface of the object, the second circumferentially closed portion of the surface of the object including at least one of the second subset of pixels that completely bounds the second contiguous region on the surface of the object; A method (300) comprising the step of designating the object (130A) protruding from the surface (120) and having the contact area (131A) with the surface (120) as one of the foreign objects (130).

15. When the object (130A) protruding from the surface (120) is designated as one of the foreign objects (130), the method (300) comprises: comparing said image with archived images of standard objects; associating the object (130A) with a particular one of the standard objects when at least one of the pixels of the first subset or the pixels of the second subset of the image matches pixels of a subset of one of the archived images corresponding to the particular one of the standard objects; and 15. The method (300) of claim 14, further comprising the step of initially associating the object (130A) with a non-standard object that is different from each other and from any one of the standard objects when none of the pixels of the first subset or the pixels of the second subset of the image match pixels of any subset of the archived images of the standard object.

16. When the object (130A) is initially associated with the non-standard object, comparing the image to archived images of non-standard objects; and 16. The method (300) of claim 15, further comprising the step of designating a particular one of the non-standard objects as a further one of the standard objects and associating the object (130A) with the further one of the standard objects when at least one of the pixels of the first subset or the pixels of the second subset of the image matches pixels of a subset of one of the archived images corresponding to the particular one of the non-standard objects.

17. 16. The method (300) of claim 15, further comprising verifying whether the object (130A) can be removed from the surface (120) using a fluid when the object (130A) is associated with the non-standard object.

18. A method (300) according to claim 17, further comprising at least one of the steps of: classifying the object (130A) as a defect in the surface (120) when the object (130A) is not removable from the surface (120) using the fluid when the object (130A) is associated with the non-standard object; or classifying the object (130A) as foreign debris when the object (130A) is removable from the surface (120) using the fluid when the object (130A) is associated with the non-standard object.

19. the first subset of pixels having a maximum grayscale value; the second subset of pixels having a minimum grayscale value; 19. The method (300) of any one of claims 14 to 18, wherein the minimum grayscale value of the pixels of the second subset is greater than the maximum grayscale value of the pixels of the first subset.

Images