Optical test equipment and its modular kit

Abstract

The housing (16) of the test device (6) is designed with a long and thin extension (16.2) similar to the tool, such as a welding gun, that produced the corresponding seam, so that the test device (6) can easily reach the weld or solder seam to be inspected, which is often in a recess or notch, i.e. between the evaluation part (16.1), in which the evaluation electronics are located, and the head part (16.3), in which the laser (14) and the light sensor (12) are located.

Description

[Technical field]

[0001] The present invention relates to optical non-contact scanning of a surface to determine the three-dimensional surface contour. [Background technology]

[0002] In industry, the dimensional accuracy of surface contours, such as the cross-sectional shape of weld seams or sealing beads, frequently needs to be inspected. Optical, non-contact scanning methods are often used here to avoid the risk of damaging the surface.

[0003] A common method is the so-called light cross-section triangulation method, in which a laser and the light fan it generates emit a light strip in a transverse direction above the surface to be scanned, for example a weld seam, and the laser light reflected from the surface in different directions and therefore towards the sensor is recorded by an optical sensor, such as a CCD sensor, from a scanning direction different from the beam direction of the light fan.

[0004] The actual contour of the workpiece surface, such as a weld seam, at the location of the incident light fan can be calculated from the shape and path of the light fan's image on the planar optical sensor, provided the angular offset between the incident light fan and the line of sight, or scanning, direction of the CCD sensor is known.

[0005] The light band is moved relatively across the surface transverse to its path, for example along a weld seam, and the entire target surface can be scanned and measured in three dimensions by repeatedly determining the contour in succession.

[0006] Optical test devices corresponding to the above method are known and, in addition to the light source, usually comprise a laser for generating a light fan, a two-dimensional planar sensor including upstream optics, electronics for evaluating the sensor signals, a power supply for all electrical components including voltage regulation, and one or more sockets for plugs to be inserted and for transferring the results to a higher-level control unit. In order to make the test device compact, the housing is usually designed in the shape of a rectangular parallelepiped.

[0007] Additionally, the test equipment housing typically includes fasteners for attachment to surrounding components.

[0008] For testing, the test device is fixedly mounted where the surface passes under the test device, whereas in the case of a stationary product surface, the test device is often mounted on and guided by a movable handler such as a robotic arm.

[0009] The surface areas where optical inspection is most frequently required include, among others, welded, soldered, glued or sealed seams, which are not located on a flat, easily accessible surface, but rather, are located at interior angles between two components, often at sharp interior angles or in other difficult to access locations. Summary of the Invention [Problem to be solved by the invention]

[0010] It is therefore an object of the present invention to provide a test device, in particular a modular kit thereof, which can be used even in places with difficult access and which can be easily configured in accordance with the spatial requirements of the task to be tested in particular. [Means for solving the problem]

[0011] This object is solved by the features of claims 1 and 16. Advantageous embodiments are disclosed in the dependent claims.

[0012] Since such seams must also be prefabricated under the same access conditions, the corresponding processing equipment, e.g. welding or soldering devices or dosing devices for applying adhesives or sealants, is often gun-shaped and is called welding guns etc. This means that a relatively long, specifically thin, extension of the device housing, at whose front end the actual working head, i.e. the welding head or dosing head, is attached, extends forward from the handle (in the case of manually guided welding guns) or the rear mounting flange (in the case of robotically guided welding guns). Thanks to this extension, processing points located in deep and narrow cavities can also be reached.

[0013] The present invention Basic Concept The solution is to house the optical test equipment not in a conventional housing that is largely rectangular, and often roughly cube-shaped, but in a housing having a shape roughly the same as the shape of the processing equipment that produced the seam or bead being inspected, such as a conventional welding gun, soldering gun, or dosing gun as described above.

[0014] Test Equipment With regard to the above, this object is achieved by having an elongated, slim housing at least in the front region, since the housing consists of a plurality of housing parts which together form a test device having a relatively thin thickness in at least the front region in the direction of maximum extension of the test device, i.e. in the direction transverse to the longitudinal or axial direction of the test device, and which is also capable of optically inspecting surface areas created by a gun-like tool of a similar shape, thereby allowing at least the test head of the test device to be brought sufficiently close to surface areas of interest, such as weld seams and sealing beads.

[0015] Such a housing according to the invention therefore consists of three parts: At the front free end of the housing Head housing The test head is a device that is not a processing device that occupies a relatively large space, but has a light source on one side and a light sensor on the other side (collectively called a test head). Located at the rear end of the housing opposite this front end Evaluation unit Specifically, an electronic processing device is disposed within the device, and the electronic processing device performs voltage regulation and signal transfer and is composed of a plurality of electronic boards, which are provided with electronic components such as resistors and diodes and are electrically connected to each other to form one or more electronic circuits. Between these two housing parts is an elongated, preferably hollow, tube-like, Extended housing part , through or along which electrical wires can be routed from the head housing section to the evaluation housing section.

[0016] An elongated extending housing part is understood in particular to mean one whose length in the direction of greatest extension, i.e. in the axial direction of the extension, is at least 5 times, more preferably 7 times, more preferably 10 times the length of its greatest transverse extension measured perpendicularly thereto.

[0017] In particular, the extending housing portion has a maximum transverse extension of at most 5cm, more preferably at most 4cm, more preferably at most 3cm, more preferably at most 2cm.

[0018] Specifically, the extended housing portion has an axial length of at least 15 cm, more preferably at least 20 cm, more preferably at least 30 cm, more preferably at least 40 cm.

[0019] Such an elongated extending housing part only serves to position the head housing part, which is clearly at least three times, preferably four times, smaller than the evaluation housing part, measured transversely to the longitudinal direction, sufficiently far from the evaluation housing part having a greater thickness, i.e. a larger transverse extension, so that even a head housing part which is designed as small as possible, specifically with regard to its transverse extension, can be inserted into a relatively narrow gap or recess.

[0020] Preferably, the three housing parts are also designed as separate housing parts which can be securely but removably connected to one another, in particular screwed together, which not only simplifies and reduces the costs of manufacturing the individual housing parts, but also allows the realization of modular kits with housing parts of different designs, so that longer or shorter test devices can be created depending on the specific application, for example by using different lengths of respective extended housing parts.

[0021] The axial directions of the individual housing sections or housing parts do not have to be aligned with one another.

[0022] Thus, the head axial direction of the head housing part can extend from its rear end to its front end at an angle to the extension axial direction of the typically straight, rod-like extension housing part, and the evaluation axial direction of the evaluation housing part need not be aligned rearward with the extension axial direction of the extension housing part, each axial direction being understood to be the direction in which the respective housing part extends to its maximum extent.

[0023] Additionally, the extended housing section may be curved or arced rather than straight depending on the work task and accessibility of the surface area to be inspected.

[0024] The length of the extension housing part in the extension axial direction is preferably at least twice the length of the head housing part in the head axial direction, more preferably at least three times, and even more preferably at least five times.

[0025] In order not to prevent the head housing part from being inserted into a narrow recess, the maximum thickness of the extended housing part, i.e. the maximum thickness measured perpendicular to its axial direction, should preferably be smaller than the maximum thickness of the head housing part, in particular less than 0.7 times the maximum thickness of the head housing part, which thickness is understood to be the maximum transverse extension measured perpendicular to its axial direction.

[0026] The test device according to the invention may further comprise the following components:

[0027] For example, the test device may comprise a flange ring which projects transversely from the evaluation housing part, or a flange plate which serves for fastening, in particular by means of screws, to a handling part such as the front end of a robot arm, etc. Preferably, such a flange ring or flange plate is arranged at the rear end of the test device, in particular at the rear end of its evaluation housing part, and at the same time as the flange plate can form the rear end wall of the evaluation housing part.

[0028] The test apparatus may further comprise a plug socket in the wall of the evaluation housing for inserting a plug for a wired electrical connection, in particular a signal connection, with higher level test equipment, e.g. a control centre for controlling the test apparatus.

[0029] Such a test device may further comprise an adapter plate, in particular an annular adapter plate, so that the flange ring or flange plate can be attached to receptacles of various designs, for example robot arms of different designs, since each robot arm usually has a different hole pattern for screwing tools and said flange ring or flange plate cannot include all hole shapes available on the market.

[0030] This is made possible by using an adapter plate which has through or threaded openings which on the one hand coincide with holes in the flange plate and on the other hand coincide with holes in, for example, the robot arm.

[0031] The test apparatus may also include a strain relief device for securing the cable plugged into the plug socket at the terminal plug, thereby preventing pulling on the cable, particularly in the direction in which the plug is pulled out of the plug socket, as well as in a direction transverse to the direction in which the cable extends.

[0032] Such a strain relief device typically comprises a longitudinally extending retaining bar, the front end of which can be fixed to the evaluation housing part, in particular to its flange plate, and at its rear end has a fixing device, e.g. a clamp device, to which the cable leading to the plug socket is fixed for strain relief.

[0033] In the case of robot arms to which such test devices are attached, a distinction should in principle be made between hollow-arm robots, which consist of several hollow arm parts successive in the longitudinal direction, and non-hollow-arm robots.

[0034] For hollow arm robots, the cables are typically routed inside each hollow arm component of the robot, whereas for non-hollow robot arms the cables must be routed along the outside of the robot arm and secured in place.

[0035] Therefore, when the test device is mounted on such a hollow arm, the plug socket is typically only mounted on the rear end wall of the evaluation housing part, specifically in the centre of its flange plate, and furthermore the strain relief, as well as the cables held therein, typically extends inside the adjacent hollow arm part of the robot.

[0036] In the case of a solid robot arm, the plug socket (often two or more separate plug sockets) is located on the peripheral wall of the evaluation housing and one or more cables are plugged into it, with the connecting cables passing through the flange plate and running along the outside of the robot arm.

[0037] In order to prevent the electrical signals transmitted through the signal line from the head housing to the evaluation housing from being adversely affected by electromagnetic radiation along this relatively long path, not only is the entire signal line formed as an electromagnetically shielded coaxial cable (i.e., a shield is provided around the signal line), but the individual wires of the multi-core signal line are also formed in this manner, thereby avoiding mutual electromagnetic influences.

[0038] This measure makes it possible in particular to realise test devices with long extending housing parts and which extend over very long distances.

[0039] Depending on the spatial situation of the surface area to be inspected, in particular if the extended housing part is not straight but curved, i.e. angled, it may be useful to be able to fix, in particular by means of screws, the extended housing part in different rotational positions, with the head part axial direction of the head housing part at an angle to the extension part axial direction of the extended housing part.

[0040] Therefore, the aforementioned fixing elements, specifically screw fixing elements such as screw holes, are preferably formed on one of the extension housing parts and the other of the head housing parts so that they can be fixed relative to each other in a number of different rotational positions, specifically around the axial direction of the extension part.

[0041] A similar configuration between the extension housing part and the evaluation housing part may also be useful, especially if the evaluation housing part is not formed symmetrically around its axial direction or if the extension housing part is not attached to the center of the evaluation housing part.

[0042] For example, in order to enable the head housing portion to reach the depth of a narrow cavity sufficiently close to the weld seam, the head housing portion is designed so that when viewed from the side of the test device, which is angled, specifically in the area of ​​the head housing portion, the head housing portion narrows from its thickest part towards its free end.

[0043] The head housing part preferably has, in a side view, an upper head end region and a lower head end region at its free end, which regions are separated from one another by a cut extending from the free end into the head housing part. One of the two head end regions preferably projects further forward in the head part axial direction than the other, and in the case of a downwardly inclined head housing part, the upper head end region preferably projects further.

[0044] This allows the light source, in particular the laser, to be located in the more protruding head end region and the sensor surface, in particular the two-dimensional sensor with the sensor surface including the upstream optics consisting of one or more optical lenses, to be located in the recessed head end region. As a result, said head housing part can be quite thin.

[0045] In this regard, it is preferred that light, specifically a light fan, is emitted from the head housing portion in a radial direction at an acute angle to the head portion axial direction (specifically, a direction corresponding to the "line of sight" of a sensor arranged in a direction transverse to a sensor surface which is also located in the narrowed end region of the head housing portion).

[0046] The optical system mounted upstream of the planar sensor consists of one or more optical lenses, which is preferably prefabricated as a unit and is inserted or screwed into the end region of the head housing part from the front of said free end side. The aforementioned optical system can be additionally protected and / or held in this mounting position by a protective cap which can be fixed to the head housing part, which of course must have a through opening for the incoming light at its front side.

[0047] The direction of light emission from a light source, which is also located in the narrow end region of the head housing portion, spreads outward at an obtuse angle with respect to the direction of light emission from the head housing portion, and this is achieved by deflection by a mirror located within the head housing portion.

[0048] By combining both measures, the head housing portion as a whole can be made narrower when viewed from the side, i.e., when viewed from the visual angle between the extension portion axial direction and the head portion axial direction, than when the light source is positioned so that the light fan is emitted from the head housing portion without being deflected by a mirror.

[0049] Furthermore, a function display of the test device, visible from the outside and illuminated by an LED inside the head housing part, is preferably provided directly on the wall of the head housing part, so that it is immediately visible at any time in the head housing part whether the test device is in operation or not. For this purpose, the wall of the head housing part is preferably provided with a light-transmitting wall part, for example a light guide part made of glass or plastic and firmly inserted into the wall.

[0050] The electronics processing section within the evaluation housing is also modular in structure, with the various electronic circuits contained therein, each serving a different purpose, being distributed across a number of circuit boards which are removably connected to one another.

[0051] On the one hand, this is an evaluation circuit board on which at least the evaluation circuitry of the sensor's signals is arranged and preferably also additional electrical and electronic components for adjusting the voltage to the needs of the sensor and light source.

[0052] This evaluation circuit board is usually a purchased component that is delivered together with the 2D sensor and adjusted accordingly, so even though it does not have any connections, it is not in the format required, for example for plug sockets and / or lasers.

[0053] Therefore, there is provided an interface circuit board which provides this facility and is electrically connected to the evaluation circuit board and which is preferably plugged into said evaluation circuit board via electrical plug contacts on both sides, so that all data and power exchanges to and from said evaluation circuit board are carried out via this interface circuit board.

[0054] Both can be fixed together to the outer wall, preferably the inner peripheral wall, of the evaluation housing part, usually by means of screws.

[0055] To provide electrical inputs and outputs to meet the requirements of the evaluation and interface circuit boards, the plug sockets are not connected directly to the interface circuit boards, but rather through an I / O circuit board which has the necessary electrical connections to each of the other circuit boards but which has socket-specific connections for the plug sockets.

[0056] Therefore, the I / O circuit board is disposed near the plug socket, specifically inside the wall into which the plug socket is inserted, that is, at a location penetrating the wall.

[0057] Therefore, there is no need to adapt the interface circuit board to each plug socket used, but rather an I / O circuit board that fits each existing plug socket can always be used.

[0058] In this way, adapting the electronic evaluation circuit to the elements, whether a plug socket or a laser, can be achieved very simply, since for this purpose it is only necessary to change and exchange the components of the circuit in the form of a corresponding circuit board.

[0059] As a result of the above design, it is possible to produce many different design variations of the test device using a relatively small number of different individual components. Modular Kit may be provided.

[0060] As a result, with regard to the housing, the modular kit may comprise at least one evaluation housing part and at least one head housing part, apart from a number of extending housing parts, which may for example have different axial lengths, such that housings for test devices extending to different lengths can be easily produced, in which three selected housing parts can be removably connected, for example by screwing them together.

[0061] In this regard, different types of extended housing parts preferably include both straight and angled or curved types depending on the spatial requirements of the existing work task.

[0062] As an additional part of the modular kit, one or preferably several different flange plates may be provided for fixing to the housing, particularly the rear end of the evaluation housing part, or as part of the evaluation housing part, so that an appropriate flange plate can be selected depending on the component to which the test device is to be attached.

[0063] If such suitable flange plates are not available, a corresponding adapter plate can be attached between the flange plate and the component supporting the test fixture, the adapter plate having fasteners (e.g., corresponding screw hole patterns) that fit the flange plate on one side and the supporting component on the other side.

[0064] Depending on the different lengths of the extending housing parts, the modular kit must also include different types of electrical signal lines and / or power supply lines, at least in terms of length, which preferably must pass through the extending housing parts and electrically connect the test head on the one hand and the evaluation part on the other hand.

[0065] In this case, each signal line, in particular each individual core of each signal line, is preferably implemented as a shielded coaxial cable, core being understood here not to mean the individual cores of a stranded wire, but the entire core conducting the same signal.

[0066] Furthermore, it is preferable to provide not just one type of plug socket, but several types that can be attached to the wall of the evaluation housing for signal transmission.

[0067] It is therefore preferable to provide not just one type of evaluation housing part, but several types, depending for example on which wall of the evaluation housing part the passages of the corresponding plug sockets are arranged.

[0068] The modular kit preferably also includes a strain relief as a modular kit component that can be attached to the evaluation housing section or flange plate or adapter plate.

[0069] With respect to the configuration of a particular electronic evaluation unit within the evaluation housing unit, the modular kit may include a variety of modular kit parts, particularly in addition to various types of housing parts.

[0070] Alternatively, the evaluation circuit board can be provided as a modular kit part which comprises at least a circuit for evaluating the signals supplied by the sensor.

[0071] Furthermore, the interface circuit board may be provided as a modular kit component that can be directly coupled to the electrical inputs / outputs of the evaluation circuit board, in particular via plug connectors, so that all signal and power inputs / outputs to the evaluation circuit board are via the interface circuit board.

[0072] Furthermore, the modular kit may include an I / O circuit board as a modular kit part, which on the one hand matches the inputs and outputs of the plug socket and on the other hand matches the inputs and outputs of the interface circuit board, i.e. not only in terms of the physical shape of the connection elements but also in terms of electrical parameters such as voltage and current.

[0073] The above-mentioned circuit board is, of course, not an empty electronic circuit board, but an electronic circuit board on which the corresponding semiconductors, i.e., the respective electronic components, have already been fully assembled and wired to form an electronic circuit. [Brief description of the drawings]

[0074] Embodiments of the invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which: [Figure 1]FIG. 1 is a side view of a prior art test setup for applying light cross-section triangulation. [Figure 2a] FIG. 2 is a front view of the test apparatus of FIG. 1. [Figure 2b] 1 is a plan view of a surface of an object. [Diagram 3] This is a light band image on a flat sensor. [Figure 4a] FIG. 2 is a side view of a test apparatus of the present invention. [Figure 4b] FIG. 2 is a plan view of a test apparatus of the present invention. [Figure 4c] FIG. 4B is an end view of the test setup of FIGS. 4a and 4b, corresponding to line CC in FIG. 4a. [Figure 4d] FIG. 4B is an end view of the test setup of FIGS. 4a and 4b, corresponding to line DD in FIG. 4a. [Figure 5a] FIG. 4a is a longitudinal section of the test setup of FIGS. 4a and 4b taken from the same direction as FIG. 4a. [Figure 5b] FIG. 4a is a longitudinal section of the test setup of FIGS. 4a and 4b taken from the same direction as FIG. 4a. [Figure 6a] FIG. 5B is a detailed enlarged view of FIGS. 5a and 5b. [Figure 6b] FIG. 5B is a detailed enlarged view of FIGS. 5a and 5b. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0075] FIG. 1 is a side view of a known rectangular shaped test device 6, in which it can also be seen how the known light section triangulation method works in principle, which will be used within the scope of the present invention in preference to other optical non-contact test methods based on the reflection of light on the surface to be examined.

[0076] In this case, a light fan 3″, typically generated by a laser as light source 14, is directed towards the surface 22 of the object 1, generating a light band 3 there, as can be seen in FIG. 2 b, which, due to its fan-shaped form, is in the form of a band with a light band length 18, as can be seen in FIG. 2 a.

[0077] The reflected light fan 3.5″ from the surface 22 of the object 1 generates a light band image 4 on a planar light sensor 12 of a detector unit 6a in the test device 6, and in an electronic processing unit 11 processing the image data recorded by the sensor 12 resultant data are calculated which reproduce the surface contour of the surface 22 along the light band 3.

[0078] The light fan 3" has a thickness, albeit a very small thickness, and the light band 3 likewise has a width, but because these dimensions are so small, for the purposes of this application the light fan 3" is identified with the geometric light fan plane 3" in which it is located, e.g., the light fan plane 3" can be said to be located in the middle of the thickness of the light fan 3".

[0079] The illuminated light band 3 is also primarily characterized by its illumination direction 3'.

[0080] In order for the light band image 4 appearing on the light sensor 12 to enable conclusions to be drawn about the actual contour of the surface 2, the scanning direction 17 of the light fan 3″ seen in the direction of the path direction 3′ of the light band 3 and the scanning direction 5 of the detector unit 6a must not coincide but must differ by a triangulation angle α.

[0081] In this case, the test device 6 is positioned such that the angle bisector 13 between the beam direction 17 of the light fan 3″ and the scanning direction 5 of the detector unit forms a perpendicular line 21 to the surface 22, i.e. these two directions each have an intermediate angle α1=α2 with respect to the angle bisector 13, which together form a triangulation angle α.

[0082] As shown in FIG. 2a, when the illuminated area illuminated by the light fan 3″ has an unevenness, such as a bump 2, what is generated as the light band 3 on the surface 22 and therefore as the light band image 4 on the sensor 12 is not a linear light band image 4, but a light band image 4 having a bulge 4a, as shown in FIG. 3, which is determined by the triangulation angle α and the position of the angle bisector 13 relative to the surface 22 of the object 1 and is different from the actual shape of the bump 2a cut along the vertical line 21.

[0083] According to FIG. 1, in the case of a structure of the surface 22 which diffusely scatters the incident light, the light incident in the region of the light band 3 in the propagation direction 3' is diffusely scattered in all directions, part of which is reflected in the direction of the detector unit 6a, i.e. in the direction of the passage 23b in the housing 16 of the test device 6.

[0084] The more reflective the surface 22 is, the less diffusely scattered the light is and it is only reflected in a specific direction. Only if this reflection direction coincides with the scanning direction 5 of the detector unit 6a, will a light band image 4 be formed on the sensor 12.

[0085] Since the position of the test device 6 and its triangulation angle α are known and the test device 6 is focused on the surface, the actual dimensions of the bump 2 on the surface 22 can be calculated from the dimensions of the light band image 4 .

[0086] As shown in FIG. 1, the test device 6 is constructed very compactly in terms of the dimensions of its main plane 20, with the light source 14, usually a laser cartridge, being arranged in the housing 16 near a passage 23a provided for the light beam, and the light sensor 12 being arranged near another passage 23b, both of which are located in one of the narrower sides of the housing 16, and in most cases between this passage 23b and the light sensor 12, a deflection via a mirror 19 of a light fan 3.5″ incident in the scanning direction 5 occurs in a direction approximately parallel to the outer edge where the passages 23a, 23b are located.

[0087] In this regard, the sensor 12 and the mirror 19 , which together constitute the detector unit 6 a , are mounted in a detector body, which is fixed in a housing 16 .

[0088] As a result, in the half of the housing 16 remote from the outer face with the passages 23a, 23b, sufficient space remains for the placement of a circuit board 24 lying parallel to the main plane 20 of the housing 16, which houses the entire electronic processing unit 11 and is connected to the sensor 12 via electrical wires, just like the light source 14. The result data determined by the processing unit 11 are output via a plug or cable output 15.

[0089] The individual images, scans S1, S2, S3 etc., generated according to the optical cross-section triangulation method are repeated in rapid succession in time to continuously observe the surface 22 of the object 1 moving in a movement direction 7 relative to the test fixture 6.

[0090] FIG. 3 shows a typical band-shaped light band image 4 of a light band 3 on a light sensor 12, including a bulge 4a formed due to a protuberance 2 on the surface 22, when the extension direction 3' of the light band 3 is transverse to the passage direction 2' of the protuberance 2.

[0091] The area of ​​the light sensor 12 is divided into a grid by rows Z1, Z2 etc. and columns R1, R2 into individual pixels, e.g. P30.17, so that an evaluation of the light sensor 12 determines which of these pixels are illuminated in the light band image 4 and have a higher brightness value than the non-illuminated pixels.

[0092] By successively performed recording scans S1, S2 etc., the entire three-dimensional contour of the area of ​​surface 22 under test can be determined.

[0093] 4a to 6b show a test device according to the present invention. Ingenious The structure is shown.

[0094] According to this, the housing 16 of the test device extends forward from the flange plate 25, and in the case of Figures 4a, 4b and 5a, 5b to the right in its general longitudinal direction 100, and has three housing parts of different designs.

[0095] Adjacent to the flange plate 25 there is a first housing part, the so-called evaluation housing part 16.1, where the flange plate 25 may be formed integrally with the peripheral wall of the evaluation housing part 16.1 and which, in side view, is thicker than the adjacent extended housing part 16.2, which extends in the same longitudinal direction 100 as the extension axial direction 16.2', and at its front end there is also a head housing part 16.3, which is thicker than the extended housing part 16.2 but, in side view, extends in the head axial direction 16.3' at an angle to the extended housing part 16.2. As will be explained below, the evaluation housing part 16.1 essentially contains the evaluation circuitry for the signals from the sensor, while the head housing part 16.2 contains the light source, i.e. the laser 14 and the light sensor 12.

[0096] Within the hollow tubular extension housing section 16.2, at least one signal line 31 and at least one power supply line 32 run from the electronics in the evaluation housing section 16.1 to the laser 14 and sensor 12 in the head housing section 16.3.

[0097] The basic idea, and most importantly, is that the head housing part 16.3 is made as small as possible, in particular with a small thickness transverse to the head part axial direction 16.3', so as to be able to optically scan surfaces that are difficult to access, for example narrow gaps and other recesses.

[0098] The flange plate 25 serves to fix the test device 6 to the component on which it is mounted, here for example the front end of a hollow robot arm 500, so that a cable 29 can pass through the inside of the robot arm 500, inserted approximately in the center of the flange plate 25, to reach the plug socket 27 and connect the test device 6 to a higher-level control device not shown.

[0099] Thus, in this case, the strain relief device 28 protrudes rearward from the flange plate, i.e. into the robot arm 500, and is constituted by a support bar 28a which also extends substantially in the main extension direction 100 of the test fixture 6 and penetrates to a certain extent into the robot arm and is provided at its free end with a fixing device, typically a clamping device 28b, in which the cable 29 leading to the plug socket 27 is clamped so as to achieve the desired strain relief.

[0100] The plug socket 27 is made up of a variable number of pins and is shown in FIG. 4c.

[0101] In the plan view of FIG. 4b, there is also an adapter plate 30 between the robot arm 500 and the flange plate 25, which serves to adapt the fastening elements, which may be for example through holes or screw holes, to the fastening elements of the robot arm 500 on the one hand and to the fastening elements of the flange plate 25 on the other hand.

[0102] In the case of the construction of figures 4a-4d, shown in longitudinal section in figure 5a, the extended housing part 16.2 is made up of two parts with respect to the circumferential direction, namely a lower sheath part, approximately U-shaped or C-shaped in cross section, which is screwed at one end to the evaluation housing part 16.1 and at the other end to the head housing part 16.3. This sheath part is open at the top and can be closed by an upper cover, which is preferably inserted at one end under the corresponding wall of the evaluation housing part 16.1 and is drawn tightly to close the opening by means of retaining screws screwed in from the lower side, i.e. the base of the sheath shape. Through these retaining screws 38, the wiring 31, 32, not shown in figure 5a, can be guided through the extended housing part 16.2.

[0103] In this application, upper and lower means that the lower is the side to which the head housing part 16.3 is inclined.

[0104] In the structure of Figure 5a, the contact surface of the front free end of the extended housing part 16.2, which is already bent at its front end, extends obliquely to the axial direction 100, i.e. the main extension direction of the test device 6, i.e. the direction in which the housing 16 extends most, which here is also the extension direction in the central region of the extended housing part 16.2.

[0105] As can be seen, the extension housing part 16.2 is not arranged in the center of the front end face of the evaluation housing part 16.1, but in its upper region.

[0106] For this reason, and since the range of movement of the robot arm can change depending on the direction of movement, it can be useful to increase or decrease the length of the central extension housing 16.2 depending on the work task, and to select different angles between the extension axial direction 16.2' of the extension housing part 16.2 and the head axial direction 16.3' of the head housing part 16.3, in particular to select different radial directions in which the head housing part 16.3 bends.

[0107] To enable this, Figure 5b also shows a second design in longitudinal section, in which the evaluation housing part 16.1, the extension housing part 16.2 and the head housing part 16.3 are separate housing parts which can be arranged adjacent to each other and fixed to each other at contact surfaces perpendicular to the axial direction 100 of the straight extension housing part 16.2.

[0108] In this way, the housing 16 can be produced in a very simple manner from a basic structure that resembles a so-called pistol shape but has different specific dimensions.

[0109] As can be seen best in the enlarged view of Figure 6a, the evaluation housing part 16.1 also consists of several parts, with a generally pot-shaped base part 16.1a having an open rear (here left) end face which can be closed by a front cover 16.1b which is inserted therein, and in the passage corresponding to this opening a plug socket 27 is pre-positioned, and an I / O circuit board 24.1 having a hole pattern corresponding to the inward-facing pins of the evaluation housing part 16.1 is mounted and soldered to the pins, and is located near the front cover 16.1b after the front cover 16.1b is attached in a direction transverse to the axial direction 100 of the evaluation housing part 16.1.

[0110] The insertion of a front cover 16.1b thus equipped is normally carried out after the I / O circuit board 24.1 has been connected to the remaining circuit boards already mounted in the evaluation housing.

[0111] These are primarily the evaluation circuit boards 24.2, which extend in the axial or longitudinal direction of the evaluation housing part 16.1 and occupy essentially its entire free space.

[0112] In parallel there is an interface circuit board 24.3 which is connected to the evaluation circuit board 24.2, preferably via plug contacts soldered on both sides, with connecting elements which fit the plug contacts or soldering points on the side facing the evaluation circuit board 24.2, but which always have the same design on the signal and power supply and discharge sides, e.g. fitting the signal lines 31 and power lines 32 and the plugs connected to them.

[0113] In principle, the interface circuit board 24.3, through which all data exchange and power supply to and from the evaluation circuit board 24.2 takes place, has approximately the same size as the evaluation circuit board 24.2.

[0114] The evaluation housing part 16.1 has outlet openings for the signal lines 31 and the power lines 32 at the bottom of the pot-shaped base part 16.1a, which outlet openings are closed by an extended housing part 16.2 which is attached to the front end of the evaluation housing part 16.1 and whose base part 16.2a is screwed onto the above-mentioned base part 16.1a, while a top cover 16.2b of the extended housing part 16.2 opposite the base part 16.2a is screwed on.

[0115] In the enlarged view of FIG. 6b, the front ends of the head housing section 16.3 and the extended housing section 16.2 are more easily discernible.

[0116] It is clear that in this construction the contact surface between these two housing parts is at an angle other than 90 degrees to the axial extension direction 16.2' of the extending housing section 16.2, namely about 45 degrees.

[0117] Figure 6b shows that the head housing part 16.3 is not only constructed with walls of approximately constant thickness, but is also a fairly solid part with openings to accommodate the parts of the test head to be mounted; these parts are One laser 14 and On the other hand, a two-dimensional planar light sensor 12 with upstream optics.

[0118] According to FIG. 6b, which is a side view in which the different extension directions of the one extending housing part 16.2 and the other head housing part 16.3 can be seen, the head housing part 16.3 is composed of an upper head end region 16.3a and a lower head end region 16.3b, and further shows that there is a cut 33 between them which opens towards the free end of the head housing part 16.3.

[0119] Here, the head end region in which the laser 14 is arranged, usually the upper head end region 16.3a, protrudes beyond the other, usually the lower head end region 16.3b.

[0120] The planar sensor 12 and the upstream optics are located in the lower head end region 16.3b and the central axis of the optics is not perpendicular to the surface of the sensor 12, but this can be taken into account in the evaluation calculations.

[0121] Furthermore, the light fan emitted by the laser 14 is not emitted directly through a light-transmitting window in the upper head end region 16.3a, but rather this light fan is first redirected by a mirror 19 so as to be emitted in a direction differing from the central axis of the camera optical system by a triangulation angle α.

[0122] The aforementioned optical system is inserted from the outside into an opening in the head housing part 16.3 and extends up to the sensor 12 inserted and mounted from the rear side of the head housing part 16.3 and is fixed in this inserted position by a protective cap 37 which is attached or screwed on and has an opening large enough to allow light in on the front side. The attachment or screwing of the protective cap 37 is possible only due to the cutout 33.

[0123] Deflection by mirrors has the advantage that the laser 14 does not have to be positioned in the extension direction of the light fan incident on the object 1, with the result that the head housing part 16.3 in this side view can be designed to be very narrow and tapered towards the front free end. [Explanation of symbols]

[0124] 1 object 2 Surface, elevation, elevation 2' Passing direction 3 Light Zone 3' Extending direction, light zone passing direction 3” light fan, fan plane 3.17” Radiation Fan 3.5” reflective fan 4. Light band image 4a Bulge 4b Recess 5 Scanning direction, observation direction, reflected light, reflection direction 6 Test Equipment 6a Detector unit 7. Direction of movement 8 Rod Lenses 8' Passing direction 8* Optical axis 9 distance 10 Diffuser 10” Diffusion Surface 11 Electronic processing equipment 12 Optical Sensor 13 Angle bisector 14 Light source 15 Plugs, cable outlets 16 Case 16.1 Evaluation unit 16.2 Extended housing section 16.3 Head housing 16.3a, 16.3b Head end area 17 Beam Direction 18 Observation width, light band length 19. Mirror 20 main plane 21 vertical 22 Surface 23a, 23b aisle 24 Circuit Board 24.1 I / O Circuit Board 24.2 Evaluation circuit board 24.3 Interface Circuit Board 25 Flange plate 26 Screw hole 27 Plug socket 28 Strain Relief Device 29 Cable 30 Adapter plate 31 Signal Line 32 Power Lines 33 Cutting 34 Function display 35 LED 36 Light guide section 37 Protective Cap 38 Setscrew 100 Axial 500 Robot Arm Z1 row R1 column S1, S2 scanning α triangulation angle Intermediate angle between α1 and α2 Deviation angle β

Claims

1. A test device (6) for optically non-contact scanning of a surface (2) of an object (1), comprising: a light source (14) emitting a light fan (3'') in a beam direction (17) onto said surface (2) to generate a light band (3) thereon; a planar light sensor (12) whose scanning direction (5) towards said light band (3) forms a triangulation angle (α) with respect to a beam direction (17) of said light fan (3″) when viewed from a passing direction (3′) of said light band (3); an electronic processing device (11) for processing the signals provided by said planar light sensor (12); A housing (16) in which the above-mentioned components are arranged, The housing (16) an evaluation housing (16.1) in which said electronic processing device (11) is arranged; a head housing part (16.3) in which the light source (14) and the planar light sensor (12) are arranged; an elongated, specifically tubular, housing extension (16.2) through which electrical lines pass between said head housing (16.3) and said evaluation housing (16.1); A test device (6).

2. The three housing parts (16.1 to 16.3) are firmly but removably connected to each other, Specifically, they are screwed together 2. A test device as claimed in claim 1, characterized in that it comprises:

3. When viewed from the side, the head axial direction (16.3') at the front end of the head housing part (16.3) forms a bending angle with respect to the axial direction of the extension housing part (16.2), Specifically, the bending angle is 10 degrees to 40 degrees, specifically, the bending angle is 20 degrees to 30 degrees.

3. A test device according to claim 1 or 2, characterized in that it comprises:

4. (Dimension settings) the maximum length of said extension housing part (16.2) in the extension axial direction (16.2') is at least twice, preferably at least three times, preferably at least five times the length of said head housing part (16.3); and / or The maximum thickness of the extension housing part (16.2) in a transverse direction perpendicular to the extension axial direction (16.2') is smaller than the maximum thickness of the head housing part (16.3) in a transverse direction thereto, specifically less than 0.7 times the maximum thickness of the extension housing part (16.2). A test device according to any one of claims 1 to 3, characterized in that it comprises:

5. (Another component) The test device (6) a flange plate (25) extending laterally from the evaluation housing part (16.1) and having a screw hole (26) for screwing at the rear end of the evaluation housing part (16.1) onto, for example, the front end of a robot arm, in particular forming the rear wall of the evaluation housing part (16.1); and / or At least one plug socket (27) provided in a wall of the evaluation housing (16.1) for electrically connecting the test device (6) to a higher-level device, and / or a strain relief (28) projecting rearward from the evaluation housing (16.1), in particular from the flange plate (25), for a cable (29) leading to the test device (6); and / or an adapter plate (30) for screwing onto a support element such as a robot arm (5) on the one hand and onto a flange plate or flange ring of the housing (16) of said test device (6) on the other hand. A test device according to any one of claims 1 to 4, characterized in that it comprises:

6. The strain relief device (28) comprises a longitudinally extending support bar (28a) at the rear end of which is provided a fastening device (28b) for an electrical cable. A test device according to any one of the preceding claims, characterized in that it comprises:

7. or, A number of plug sockets are arranged on the peripheral wall of the evaluation housing part (16.1), specifically arranged one after the other in the axial direction and / or spaced apart.

7. A test device according to any one of the preceding claims, characterized in that it comprises:

8. (Coaxial cable) The electric signal line (31) is designed as an electromagnetically shielded coaxial cable, in particular the individual wires of said electric signal line are individually shielded as a coaxial cable. A test device according to any one of the preceding claims, characterized in that it comprises:

9. (Rotary) The fastening device, in particular the screw element, has fastening elements fixed to at least one end of the extended housing part (16.2) and to the other end of the evaluation housing part (16.1) and / or the head housing part (16.3), the fastening device being designed so that the extended housing part (16.2) can be fastened to the extended housing part (16.2) in different rotational positions around the longitudinal direction (100) of the test device in the region of the contact surface of the extended housing part with the other adjacent housing part. A test device according to any one of the preceding claims, characterized in that it comprises:

10. (Head part narrows toward the front) The head housing portion (16.3) narrows from its thickest point toward the front when viewed from the side, Specifically, it has an upper head front end region (16.3a) and a lower head front end region (16.3b) separated from each other by a notch (33), One of the two head end regions (16.3a, 16.3b), specifically the upper head end region (16.3a), protrudes in the head axial direction (16.3') beyond the other head end region (16.3b). A test device according to any one of the preceding claims, characterized in that it comprises:

11. The light source (14), in particular the laser (14), is arranged in the further protruding head end region (16.3a), and the planar light sensor (12), in particular the planar light sensor (12) including the upstream optics, is arranged in the recessed head end region (16.3b). A test device according to any one of the preceding claims, characterized in that it comprises:

12. the direction of the light beam from the head housing part (16.3) is at an acute angle to the axial direction of the optical system of the planar light sensor (12) in the narrowing end region of the head housing part (16.3); The direction of the light beam from the light source arranged in the narrowed end region is deflected by the mirror (19) at an obtuse angle to the direction of the light beam from the head housing part (16.3). Test device according to any one of the preceding claims, characterized in that it comprises:

13. A function display section (34) for the test device (6) is provided on a wall of the head housing section (16.3), specifically on its upper side, and is illuminated by an LED (35) and visible from the outside, Specifically, it takes the form of a semi-transparent wall portion embedded in the wall, specifically a light guide portion (36). A test device according to any one of the preceding claims, characterized in that it comprises:

14. The objective lens is inserted, in particular screwed, into the end region of the head housing part (16.3) from the free front side, The objective lens is held and / or protected by a protective cap (37) that has an opening for reflected light and can be fixed to the head housing part (16.3). Test device according to any one of the preceding claims, characterized in that it comprises a

15. (Components in the evaluation housing) Within the evaluation housing (16.1) an I / O circuit board (24.1) for providing a socket-specific connection for said plug socket while providing the necessary electrical connections to other circuit boards, said I / O circuit board (24.1) being located in particular close to the plug socket (27) to which it is electrically connected, and in particular fixed to a rear end wall of said evaluation housing part (16.1); an evaluation circuit board (24.2) carrying at least an evaluation circuit for the sensor signals; and an interface circuit board (24.3) electrically connected to the light source and the sensor and having electrical inputs and outputs that meet the requirements of the I / O circuit board. A test device according to any one of the preceding claims, characterized in that it comprises:

16. A modular kit for creating different variants of a test device (6) comprising a housing (16) and a number of electrical components housed therein, in particular electrical circuit boards (24.1-24.3), in particular a test device (6) according to any one of claims 1 to 15, said kit comprising: The modular kit of housings (16) comprises the following modular kit parts: at least one type of evaluation housing part (16.1) capable of accommodating said electronic processing device (11); At least one type of head housing part (16.3) capable of housing the light source (14) and the planar light sensor (12); a plurality of different elongated tubular extension housing parts (16.2) of different lengths, specifically elongated in an extension axial direction (16.2'), through or along which electrical lines can be routed between the head housing part (16.3) and the evaluation housing part (16.1); The three housing parts (16.1 to 16.3) are designed to be removably but securely connected to one another, in particular by screwing. A modular kit comprising:

17. The various types of extended housing sections (16.2) include both straight and angled or curved types.

17. A modular kit according to claim 16.

18. As another modular kit part: a flange plate (25) for fastening to the rear end face of at least one evaluation housing part (16.1) or as the rear face of said evaluation housing part (16.1); and / or an adapter plate (30) for fixing to said flange plate (25); and / or At least one strain relief for fastening to the evaluation housing part (16.1) or to the flange plate (25) or to the adapter plate (30), and / or At least one, preferably several types of plug sockets for arranging one type of evaluation housing part (16.1) on the wall, and / or There are provided a variety of electric signal lines having different forms of electromagnetically shielded coaxial cables, specifically different lengths, and specifically individual wires of the electric signal lines are individually shielded as coaxial cables.

18. Modular kit according to claim 16 or 17, characterized in that

19. As a further modular kit part, specifically for placement in said evaluation housing (16.1), an I / O circuit board (24.1) for providing the necessary electrical connections to other circuit boards, in particular for providing plug sockets with socket-specific connections which can be connected to at least one plug socket; and / or an evaluation circuit board (24.2) carrying at least an evaluation circuit for the sensor signals and / or An electrically enabled interface circuit board (24.3) is mounted on the light source (14) and sensor (12) and has electrical inputs and outputs that meet the requirements of the I / O circuit board (24.1). Modular kit according to any one of claims 16 to 18, characterized in that it

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