System and method for inspection of ceramic bearing rollers

Abstract

An inspection assembly for ceramic bearing rollers. The inspection assembly includes a base and a camera supported by the base. The camera is configured to capture images of the roller positioned within an inspection region defined between the base and the camera. The inspection assembly also includes a support block positioned in the inspection region and configured to support the roller, a first light source configured to direct a first type of light to the inspection region, and a second light source configured to direct a second type of light to the inspection region. The support block is pivotable relative to the base to adjust an orientation of the roller. The second type of light is different than the first type of light.

Description

SYSTEM AND METHOD FOR INSPECTION OF CERAMIC BEARING ROLLERSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 581,867, filed September 11, 2023, the entire contents of which are hereby incorporated by reference.BACKGROUND

[0002] Rolling element bearings with ceramic rollers are widely used in various industrial processes, such as manufacturing, aerospace, printing, and paper production due to their excellent thermal and wear-resistant properties. These rollers ensure smooth and efficient material movement. However, defects or damage to these ceramic rollers can lead to quality issues, downtime, and increased maintenance costs.

[0003] Current inspection methods for ceramic rollers are often time-consuming and lack a deterministic way for repeatable roller presentation and guaranteeing inspection of 100% of the roller surface. Ceramic rollers undergo quality inspections to identify any defects as per specific visual inspection standards. Traditionally, these inspections are conducted at high magnification using white light and the Fluorescence Penetrant Inspection (FPI) techniques.

[0004] The rollers are inspected under a microscope to attain the desired magnification. If a defect is indicated an operator might increase the magnification to investigate the indication. To highlight a defect under a microscope two types of lighting setup are used - white light and dark light. White light inspection involves illuminating the Field of View (FOV) with white light to visualize any defects. Multiple directional lights might be used to highlight the defects. This requires an operator to physically manipulate and switch between the various directional lights.

[0005] The dark light (ultraviolet light) inspection is part of the Fluorescence Penetrant Inspection (FPI) technique which helps in highlighting defects like cracks. In this technique, a part is allowed to soak in a penetrating fluid which allows the fluid to penetrate a defect. The part is washed and then illuminated with a UV light. The penetrant fluid has fluorescent properties under UV light and when exposed, any defects like cracks would fluoresce.

[0006] The setup under the microscope needs to be changed to manipulate the part under the microscope and to set up a UV light source. The rollers are rotated and / or translated under the microscope manually with or without the use of parallel rolls to support the roller under inspection.SUMMARY

[0007] In one aspect, the invention provides an inspection assembly for ceramic bearing rollers. The inspection assembly includes a base and a camera supported by the base. The camera is configured to capture images of the roller positioned within an inspection region defined between the base and the camera. The inspection assembly also includes a support block positioned in the inspection region and configured to support the roller, a first light source configured to direct a first type of light to the inspection region, and a second light source configured to direct a second type of light to the inspection region. The support block is pivotable relative to the base to adjust an orientation of the roller. The second type of light is different than the first type of light.

[0008] In another aspect, the invention provides an inspection assembly for ceramic bearing rollers. The inspection assembly includes a base and a camera supported by the base. The camera defines a camera axis. The camera is configured to capture images of a roller positioned within an inspection region defined between the base and the camera. The inspection assembly also includes a support block positioned in the inspection region and configured to support the roller, a first light source configured to direct a first type of light to the inspection region, and a second light source configured to direct a second type of light to the inspection region. The first light source defines a first axis. The first axis and the camera axis define a first angle. The second type of light is different than the first type of light. The second light source defines a second axis. The second axis and the camera axis define a second angle different than the first angle.

[0009] In yet another aspect, the invention provides a method of inspecting ceramic bearing rollers with an inspection assembly. The method includes providing the inspection assembly including a camera, a support block configured to support the ceramic bearing rollers, a first light source, a second light source, and a control system, the camera defining a camera axis. The method also includes providing a first roller including a first geometry and defining alongitudinal axis, loading the first roller into the support block, determining an operational orientation of the first roller with the control system, orienting the first roller with the support block such that the longitudinal axis is perpendicular to the camera axis, illuminating a first surface of the first roller with the first light source or the second light source, capturing an image of the first roller with the camera, and removing the first roller from the support block.BRIEF DESCRIPTION OF THE FIGURES

[0010] FIG. 1 is a perspective view of an inspection assembly for a roller.

[0011] FIG. 2 is a schematic side view of a roller and illumination assembly of the inspection assembly of FIG. 1.

[0012] FIG. 3 is another schematic side view of a roller and the illumination assembly of FIG. 2.

[0013] FIG. 4 is a sample image of a tapered roller viewed by the inspection assembly of FIG. 1.

[0014] FIG. 5 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller under bright field illumination.

[0015] FIG. 6 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller under dark field illumination.

[0016] FIG. 7 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller including a gouge defect.

[0017] FIG. 8 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller including a tear defect.

[0018] FIG. 9 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller including a scuff defect.

[0019] FIG. 10 is a sample image of a roller viewed by the inspection assembly of FIG. 1, the roller under ultraviolet illumination and including a crack defect.

[0020] FIG. 11 is a sample image of a roller viewed by the inspection assembly of FIG. 1 , the image including defects identified by software.

[0021] FIG. 12 is a perspective view of another inspection assembly for a roller.

[0022] DETAILED DESCRIPTIONERROR! REFERENCE SOURCE NOT FOUND.FIG. 1 illustrates an inspection assembly 10 (also referred to as a body inspection station 10 or a first inspection assembly 10). The inspection assembly 10 is configured to inspect a roller 14 (shown in FIG. 2). More specifically, the inspection assembly 10 is configured to inspect an outer surface 40 of the roller 14. The outer surface 40 is positioned between two ends 16 of the roller 14 (shown in FIG. 2). The roller 14 can be a ceramic bearing roller, a steel bearing roller, a plastic bearing roller, etc. The inspection assembly 10 includes a base 18. The base 18 includes a first surface 22 and a second surface 26 opposite the first surface 22. The first surface 22 is configured to engage a ground surface, a table, etc. to support the inspection assembly 10. The inspection assembly 10 includes a post 30 coupled to the base 18. The post 30 extends from the second surface 26 in a direction away from the first surface 22. The illustrated inspection assembly 10 includes two posts 30. Each post 30 extends from the second surface 26 in a direction away from the first surface 22. In other embodiments, the inspection assembly 10 can include fewer or more posts 30 (e.g., one, three, etc.). The inspection assembly 10 also includes a platform 34 coupled to the pair of posts 30. The platform 34 is adjustable along a height of the posts 30.

[0023] With continued reference to FIG. 1, the inspection assembly 10 includes an imaging device 38 coupled to the platform 34. In other embodiments, the imaging device 38 can be coupled to the posts 30. The imaging device 38 can be, for example, a high-resolution camera. The imaging device 38 is configured to capture images of rollers 14. The imaging device 38 captures detailed images of the outer surface 40 (also referred to as a roller surface 40) of the rollers 14. The imaging device 38 captures minute defects and variations on the outer surface 40. The zoom or magnification of the imaging device 38 is adjustable to improve the image of the outer surface 40. The imaging device 38 is equipped with a motorized lens 42 to capture both macro and micro-level details on the surface of the rollers 14. The imaging device 38 is movable with the platfomi 34 along the height of the posts 30.

[0024] With continued reference to FIG. 1 , the inspection assembly 10 includes an illumination system 46. The illumination system 46 is coupled to a carrier 50, which is coupled to the imaging device 38. In some embodiments, the carrier 50 can be coupled to the posts 30, the platform 34, or any suitable component of the inspection assembly 10 to secure the illumination system 46. The illumination system 46 provides lighting conditions sufficient for capturing clear images of the outer surface 40 of each roller 14. The illumination system 46 includes a first light source 54 and a second light source 58. The first light source 54 can emit a first type of light. The first type of light can be associated with a first wavelength or a first range of wavelengths. The second light source 58 can emit a second type of light. The second type of light can be associated with a second wavelength or a second range of wavelengths. The second type of light can be different than the first type of light. For example, the first type of light can have a first wavelength or range of wavelengths and the second light can have a second wavelength or range of wavelengths that is different than the first wavelength or range of wavelengths. In some embodiments, the second range of wavelengths can overlap with the first range of wavelengths. In other embodiments, the second range of wavelengths does not overlap with the first range of wavelengths. In one example embodiment, the first type of light can be white light, and the second type of light can be ultraviolet (UV) light. As such, the first type of light can have a wavelength range of four hundred nanometers (nm) to seven hundred nm (400 nm to 700 nm), and the second type of light can have a wavelength range of one hundred nm to three hundred eighty nm (100 nm to 380 nm). The first light source 54 emitting white light can be adjustable for bright field illumination and dark field illumination. The second light source 58 emitting UV light can be used for Fluorescence Penetrant Inspection (FPI) techniques. The illumination system 46 including the first light source 54 and the second light source 58 allows a user to switch between white light (bright field and dark field) and UV light (FPI imaging) without requiring any mechanical changes to the illumination system 46. The respective first and second types of lights can alternatively be defined by a frequency or range of frequencies. It should be appreciated that the wavelength of light is related to the frequency. More specifically, the wavelength multiplied by the frequency is equal to the speed of light. The respective first and second types of lights can also alternatively be defined by a temperature or a range of temperatures.

[0025] The first light source 54 includes four bar lights 62 coupled to the carrier 50. Each bar light 62 is angled to provide illumination to the outer surface 40 of the roller 14. Each bar light 62 can be angled to sufficiently illuminate the outer surface 40 based on the curvature or geometry of the roller 14 under inspection. The bar lights 62 are sufficiently illuminated when any defects on the outer surface 40 can be seen through the imaging device 38. For example, it may be desired to have the bar lights 62 at a different angle when a tapered roller 14 is under inspection than when a cylindrical roller 14 is under inspection. For illumination of the body of the roller 14, two of the bar lights 62 provide a low angle lighting condition. This lighting condition highlights defects 65 as shown in FIG. 6. The lighting condition can be dark field illumination. The other two bar lights 62 can provide a higher angle lighting condition that highlights defects 65 as shown in FIG. 5. The lighting condition can be bright field illumination. The four bar lights 62 can be arranged around the vertical optical axis (e.g., at 90-degree intervals, substantially forming four edges of a rectangle or square). In some embodiments, the first light source 54 can include fewer or more bar lights 62 (e.g., one, three, four, etc.).

[0026] The second light source 58 includes two UV lights 64 coupled to the carrier 50. The UV lights 64 can be mounted above the first light source 54 or between adjacent bar lights 62. In the illustrated embodiment, the UV lights 64 are located at two corners of the square of bar lights 62. In some embodiments, the second light source 58 can include fewer or more UV lights 64 (e.g., one, three, four, etc.). For example, the second light source 58 can include four UV lights 64 located at each comer of the square of bar lights 62. The second light source 58 can be used for detection of micro-cracks. The UV light is absorbed by the penetrant fluid on the outer surface 40 of the roller 14 so that it can fluoresce. FIG. 10 illustrates one defect 65 in the form of a C-crack detected under the FPI inspection.

[0027] With continued reference to FIG. 1, the illumination system 46 includes a third light source 66. The third light source 66 can emit the first type of light. The third light source 66 can be an on-axis light that comes through the optical pathway of the lens 42 from an LED source connected to the lens 42. The third light source 66 provides a manual focus available on the LED light attachment to the lens 42 that allows for focusing of the light spot. The intensity of the third light source 66 can be controlled programmatically. Stated another way, the intensity of the third light source 66 can be automatically adjusted by the inspection assembly 10. Images of the rollersurface 40 can then be sequentially captured by the imaging device 38 at varying intensity levels of the third light source 66. Alternatively, the intensity of the third light source 66 can be adjusted manually by an operator. FIGS. 7-9 respectively illustrate images with one defect 65 in the form of a gouge, one defect 65 in the form of a tear, and one defect 65 in the form of a scuff seen under lighting from the third light source 66.

[0028] With continued reference to FIG. 1, the inspection assembly 10 includes a linear actuation assembly 70. The linear actuation assembly 70 is coupled to the second surface 26 of the base 18. The linear actuation assembly 70 includes a first stage 74, a second stage 78, and a third stage 82. Each of the first stage 74, the second stage 78, and the third stage 82 is selectively linear actuatable in a different direction. In one embodiment, the first stage 74 can move in a first direction along the second surface 26 (e.g., an X-direction), the second stage 78 can move in a second direction towards and away from the second surface 26 (e.g., a Z-direction), and the third stage 82 can move in a third direction along the second surface 26 perpendicular to the first direction (e.g., a Y-direction).

[0029] With continued reference to FIG. 1, the inspection assembly 10 includes a part trap stage 86, a first riser 90, and a first spindle 94 (also referred to as a part trap spindle 94). The part trap stage 86 is coupled to the third stage 82. The first riser 90 is coupled to the part trap stage 86. The first riser 90 can be slidable relative to the part trap stage 86. The first spindle 94 is coupled to the first riser 90. The first spindle 94 can be slidable with the first riser 90 relative to the part trap stage 86. The first spindle 94 is configured to engage the roller 14. In some embodiments, the part trap spindle 94 includes a pin plunger at its end with an internal spring that absorbs the compression needed to hold the roller 14.

[0030] With continued reference to FIG. 1, the inspection assembly 10 includes a second riser 98, a part rotation stage 102, and a second spindle 106 (also referred to as a rotation spindle 106). The second riser 98 is coupled to the third stage 82. The part rotation stage 102 is coupled to the second riser 98. The part rotation stage 102 is configured to rotate relative to the second riser 98. The second spindle 106 is coupled to the part rotation stage 102. The second spindle 106 is configured to rotate with the part rotation stage 102 relative to the second riser 98. The second spindle 106 is configured to engage the roller 14 to rotate the roller 14.

[0031] The inspection assembly 10 includes a third riser 1 10, a tilt stage 114, and a support block 118 (also referred to as a V-block 118). The third riser 110 is coupled to the third stage 82. The third riser 110 can be slidably coupled to the third stage 82. The third riser 110 is positioned between the first riser 90 and the second riser 98. The tilt stage 114 is coupled to the third riser 110. More specifically, the tilt stage 114 is pivotably coupled to the third riser 110. The tilt stage 114 is configured to pivot relative to the third riser 110 to orient the roller 14 in a desired position. The tilt stage 114 allows the inspection assembly 10 to inspect different rollers 14 having cylindrical and tapered shapes. The tilt stage 114 is specifically beneficial for allowing the inspection assembly 10 to inspect tapered rollers 14 (shown in FIG. 4). For tapered rollers 14, the tilt stage 114 is rotated by half of the included angle of the tapered roller 14 so that a longitudinal axis 120 of the roller 14 is horizontal (e.g., perpendicular to a camera axis 126, parallel with a ground surface or a plane defined by the base 18, etc.). The support block 118 is coupled to the tilt stage 114. The support block 118 is configured to pivot with the tilt stage 114 relative to the third riser 110. The illustrated support block 118 includes a V-shape to receive the roller 14. In other embodiments, the support block 118 can include any suitable shape to receive the roller 14.

[0032] With continued reference to FIG. 1, the inspection assembly 10 defines an inspection region 122 (also referred to as an inspection area 122). The inspection region 122 is defined between the base 18 and the imaging device 38. The roller 14 is held on the support block 1 18 within the inspection region 122 during operation.

[0033] With reference now to FIGS. 2 and 3, the imaging device 38 defines the camera axis 126 extending along the imaging device 38. The camera axis 126 extends through or intersects the roller 14. More specifically, the camera axis 126 extends perpendicular to a longitudinal axis 120 of the roller 14. In some embodiments, the camera axis 126 can extend substantially perpendicular or oblique to the longitudinal axis 120. The camera axis 126 is oriented relative to the roller 14 to allow the imaging device 38 to capture images of the outer surface 40 of the roller 14.

[0034] The imaging device 38 can be used for any type of roller 14 (e.g., cylindrical, tapered, etc.) and for any type of light (e.g., the first light source 54, the second light source 58, the thirdlight source 66, etc.). Between different tests (e.g., different types of light) on the roller 14, the imaging device 38 remains the same and the lens 42 is adjusted. As such, a user does not need to spend time swapping out different imaging devices between different tests or moving the roller 14 to different inspection stations. The efficiency of the inspection assembly 10 is improved by having only one imaging device 38.

[0035] With continued reference to FIGS. 2 and 3, the third light source 66 further defines the camera axis 126. The third light source 66 selectively emits light along the camera axis 126 into the inspection region 122 to illuminate the outer surface 40 of the roller 14 and improve the visibility of any defects on the outer surface 40.

[0036] With continued reference to FIGS. 2 and 3, each bar light 62 defines a first axis 138. Each bar light 62 selectively emits light along the respective first axis 138 into the inspection region 122 to illuminate the outer surface 40. Each first axis 138 extends through or intersects the roller 14. A first angle 142 (also referred to as a low angle 142) is defined between each first axis 138 and the longitudinal axis 120. Each first angle 142 can be adjusted by pivoting each bar light 62. In the illustrated embodiment, the first angle 142 of each bar light 62 is identical. In other embodiments, the first angle 142 of each bar light 62 can be different.

[0037] With reference to FIG. 2, each UV light 64 defines a second axis 146. Each UV light 64 selectively emits light along the respective second axis 146 into the inspection region 122 to illuminate the outer surface 40. Each second axis 146 extends through or intersects the roller 14. A second angle 150 is defined between the second axis 146 and the longitudinal axis 120. The second angle 150 is adjustable by adjusting an orientation of each UV light. In the illustrated embodiment, the second angle 150 of each UV light 64 is identical. In other embodiments, the second angle 150 of each UV light 64 can be different. The second angle 150 is greater than the first angle 142.

[0038] The first and second angles 142, 150 can also be defined by the respective first and second axes 138, 146 and the longitudinal axis 120. In this case, the first angle 142 is greater than the second angle 150.

[0039] With returned reference to FIG. 1 , the inspection assembly 10 includes a control system 154. The control system 154 controls operation of the other components of the inspection assembly 10. The control system 154 controls the operation of any or all of the illumination system 46, movement of the linear actuation assembly 70, pivoting of the tilt stage 114, rotation of the second spindle 106, etc. In some embodiments, the control system 154 can be physically connected to one or more of the other components of the inspection assembly 10. In other embodiments, the control system 154 can be physically separate from the other components of the inspection assembly 10. For example, the user interface of the control system 154 can be on an external computer.

[0040] The control system 154 includes a user interface, which is configured to receive inputs from a user to control operation of the inspection assembly 10. The control system 154 can also include a database of information on different rollers 14. For example, the database can include any or all of a length, width, diameter, taper angle, etc. for any number of rollers 14. The information about each roller 14 can be associated with a specific part number of the roller 14. The user can input or select the part number for the associated roller 14 that is being inspected to the control system 154. The control system 154 can determine a desired or operational orientation of the respective roller 14 based on the roller 14. The control system 154 can then automatically move the linear actuation assembly 70 and pivot the tilt stage 114 to properly orient the roller 14 (i.e., to the operational orientation) relative to the imaging device 38. In some embodiments, the user can then select a desired light source and control rotation of the roller 14 via the second spindle 106. In other embodiments, the control system 154 can automatically turn on the desired light source and rotate the second spindle 106.

[0041] The control system 154 can also ensure that the entire roller surface 40 is imaged by the imaging device 38. The size and dimensions of the roller surface 40 can be included within the database. As such, the control system 154 can automatically move the roller 14 (e.g., by the rotation spindle 106 and the linear actuation assembly 70) to capture a series of images of the entire roller surface 40. The control system 154 can then stitch the series of images together to create one image of the entire roller surface 40. The control system 154 can then display the image of the entire roller surface 40 on the user interface, send the image to an external computer, or display the image in any suitable way for the user to view the image.

[0042] The control system 154 can be used to view inspection results, access historical data, and / or generate reports. The user interface also allows users to customize parameters for defect identification and display inspection results, allowing operators to make informed decisions.

[0043] The control system 154 can include inspection software. The inspection software can analyze the captured image(s) taken by the imaging device 38. The captured images are processed using advanced image analysis algorithms. The inspection software identifies defects on the roller surfaces 40. The defects can be cracks, chips, wear patterns, and other anomalies on the roller surfaces 40.

[0044] FIG. 11 illustrates a sample image with the defects 65 identified and displayed by the inspection software. The sample image includes a number of identification boxes 158. The identification boxes 158 indicate some of the defects 65 and make the defects 65 more visible to the operator. The consistent imaging can also allow for the captured images to be used as a training set for an Artificial Intelligence based inspection model.

[0045] FIG. 12 illustrates an inspection assembly 210 (also referred to as an end inspection station 210 or a second inspection assembly 210). The end inspection station 210 is similar to the body inspection station 10. However, whereas the body inspection station 10 is configured to inspect the outer surface 40 of the roller 14, the end inspection station 210 is configured to inspect the ends 16 of the rollers 14. Components in the end inspection station 210 are labeled the same as the like components in the body inspection station 10. For example, the end inspection station 210 includes the imaging device 38, the lens 42, the illumination system 46, and the linear actuation assembly 70. Thus, the end inspection station 210 provides many of the same features and advantages as the body inspection station 10 of the preceding disclosure. Only differences between the end inspection station 210 and the body inspection station 10 are described herein.

[0046] The inspection assembly 210 includes a mounting block 214 (also referred to as a support block 214). The mounting block 214 is coupled to the third stage 82. The mounting block 214 is in replacement of the tilt stage 114 and the support block 118. One end 16 of the roller 14 (e g., a bottom end) is configured to engage and rest on the mounting block 214. The opposite end 16 (e.g., upper end) is selectively illuminated by the illumination system 46. Theopposite end 16 of the roller 14 is configured to be imaged by the imaging device 38. The control system 154 can automatically move the roller 14 (e.g., by the linear actuation assembly 70) to capture a series of images of the entire end 16. The control system 154 can then stitch the series of images together to create one image of the entire roller surface 40. In other constructions, the entire end 16 is shown in a single image of the imaging device 38. The roller 14 can be flipped by the user, such that the end 16 that previously engaged the mounting block 214 is now illuminated by the illumination system 46 and configured to be imaged by the imaging device 38.

[0047] During operation, the outer surface 40 of one roller 14 (a first roller 14) can be inspected first. As such, the roller 14 is loaded onto the support block 118 of the inspection assembly 10. An operator can select the part number of the roller 14 on the user interface of the control system 154. The operator can, for example, select the part number from a pull-down menu on the user interface. The control system 154 can determine the operational orientation of the roller 14 based on the part number. The inspection assembly 10, in response, automatically moves the linear actuation assembly 70 to position the support block 118 under the imaging device 38 and motorized lens 42 and also pivots the tilt stage 114 such that the roller 14 is oriented at the operational orientation. This positioning is automated so that the roller surface 40 is in focus based on the geometry of the roller 14. The positioning also enables rollers 14 of different sizes to be correctly positioned under the imaging device 38 so that the images acquired are in focus and are at the same magnification for all parts as desired by the inspection requirements. The part trap spindle 94 on the part trap stage 86 extends to trap the roller 14 against the rotation spindle 106 mounted on the part rotation stage 102. The roller 14 is held in place between the rotation spindle 106 and the part trap spindle 94. Next, the support block 118 is lowered. The user interface of the control system 154 displays a live image of the roller surface 40. The inspection assembly 10 can automatically rotate the roller 14 under the imaging device 38 by rotating the rotation spindle 106 on the part rotation stage 102 at a user controllable speed or can be jogged manually as needed. The imaging device 38 can capture a series of images of the entire outer surface 40. The user can optionally move the roller 14 to inspect a different portion of the roller 14. The user can also optionally adjust the magnification / zoom of the imaging device 38 to improve the image. The control system 154 also allows the user to switch between individual or a combination of lighting options (the first light source 54, the second light source 58, the third light source 66) as needed during the inspection. The first,second, and third lighting sources 54, 58, 66 are pre-set so that they all illuminate the inspection region 122 at all times irrespective of the roller geometry. Both the white light and the dark light (FPI) inspections can be done on the same setup without the need of any mechanical changes or adjustments. More specifically, the imaging device 38 does not need to be swapped out, nor is the roller 14 removed. Rather, the lens 42 is adjusted (e.g., by the control system 154) between different light modes. Switching between the modes or configurations can be done automatically by software or by using manual switches. Switching the UV lights and / or the white lights can be done by manually switching the lights On / Off or controlling via the software interface. When switched between the white light and FPI modes, the gain and exposure time for the images are changed internally.

[0048] When a tapered roller 14 is scanned, the field of view (FOV) of the roller 14 is small due to desired inspection magnification. Over this FOV, the slope of the roller surface 40 is less than the depth of field (DOF) of the lens 42 so that the length of the roller 14 in view is in focus even though it is at an angle to the lens 42. As the strip of the roller surface 40 is inspected and the next strip is to be inspected, the entire assembly holding the roller 14 moves laterally by the FOV (with overlap). Also, the assembly can be raised or lowered so the distance from the outer surface 40 of the roller 14 to the lens 42 is a constant, resulting in the various images of different rollers 14 being taken at the same magnification. Once a user has completed the inspection, they can select for the roller to be unloaded from the system automatically and presented to the operator. All the system and part specific parameters are automatically saved with the images for the part under inspection. The series of images captured of the entire roller surface 40 can be stitched together by the control system 154 to create one image of the entire roller surface 40.

[0049] Either before or after the first roller 14 has been inspected at the inspection assembly 10, the first roller 14 can be placed into the inspection assembly 210 to inspect the ends 16 of the first roller 14. One end 16 can be placed in engagement with the mounting block 214. An operator can select the part number of the roller 14 on the user interface of the control system 154. In some embodiments, the control system 154 can be in connection with both the inspection assembly 10 and the inspection assembly 210. In these embodiments, the operator may not need to re-input the part number of the roller 14. The control system 154 can determine the operational orientation of the roller 14 based on the part number. The inspection assembly 210,in response, automatically moves the linear actuation assembly 70 to position the roller 14 under the imaging device 38 and motorized lens 42. This positioning is automated so that the end 16 is in focus based on the geometry of the roller 14. The positioning also enables rollers 14 of different sizes to be correctly positioned under the imaging device 38 so that the images acquired are in focus and are at the same magnification for all parts as desired by the inspection requirements. The user interface of the control system 154 displays a live image of the end 16. The inspection assembly 210 can automatically move the roller 14 under the imaging device 38 by moving the linear actuation assembly 70 at a user controllable speed or can be jogged manually as needed. The imaging device 38 can capture a series of images of the end. The user can optionally move the roller 14 to inspect a different portion of the roller 14. The user can also optionally adjust the magnification / zoom of the imaging device 38 to improve the image.

[0050] Once a series of images of the end 16 is captured, the operator can remove the roller 14 from the inspection region 122 and then re-insert the roller 14 into the inspection region 122 with the other end 16 engaging the mounting block 214. The same process can be conducted for the other end 16 as described above for the first end 16. The series of images captured of both ends can be stitched together by the control system 154 to create one image of each end 16.

[0051] Once the ends 16 and the outer surface 40 of the first roller 14 have been inspected, a new or second roller 14 can be inspected. The second roller 14 can have a second geometry. The second geometry can be different than the geometry of the first roller 14. The second roller 14 can then be manipulated and analyzed by the inspection assemblies 10, 210 in the same way as described above with reference to the first roller 14.

[0052] The present invention is a system designed to inspect ceramic rollers efficiently and accurately. The system combines advanced material handling, imaging and lighting technology, and user-friendly interface components to provide an all-encompassing solution for roller inspection. By using this system, manufacturers and operators can identify defects, anomalies, and wear patterns on ceramic rollers, enabling them to take preventive measures before more significant issues arise.

Claims

CLAIMSWhat is claimed is:

1. An inspection assembly for ceramic bearing rollers, the inspection assembly comprising: a base; a camera supported by the base, the camera configured to capture images of a roller positioned within an inspection region defined between the base and the camera; a support block positioned in the inspection region and configured to support the roller, the support block pivotable relative to the base to adjust an orientation of the roller; a first light source configured to direct a first type of light to the inspection region; and a second light source configured to direct a second type of light to the inspection region, the second type of light different than the first type of light.

2. The inspection assembly of claim 1, wherein the camera defines a camera axis, the roller defines a longitudinal axis, and the support block is pivotable relative to the base to orient the longitudinal axis perpendicular to the camera axis.

3. The inspection assembly of claim 1, further comprising a linear actuation assembly coupled to the base, wherein the support block is coupled to the linear actuation assembly, and wherein the linear actuation assembly is configured to move the support block within the inspection region.

4. The inspection assembly of claim 1, further comprising a rotation assembly including a spindle and a pin, wherein the roller includes a first end and a second end opposite the first end, and wherein the spindle is configured to engage the first end and the pin is configured to engage the second end in response to the support block adjusting the orientation of the roller.

5. The inspection assembly of claim 1, further comprising a control system connected to the support block, wherein the control system is configured to receive an input, and wherein thesupport block is configured to adjust the orientation of the roller in response to the control system receiving the input.

6. The inspection assembly of claim 1, wherein the first type of light is white light, and wherein the second type of light is ultraviolet light.

7. The inspection assembly of claim 1, further comprising a linear actuation assembly coupled to the base and the support block, wherein the linear actuation assembly is configured to adjust a position of the support block relative to the camera.

8. An inspection assembly for ceramic bearing rollers, the inspection assembly comprising: a base; a camera supported by the base, the camera defining a camera axis, the camera configured to capture images of a roller positioned within an inspection region defined between the base and the camera; a support block positioned in the inspection region and configured to support the roller; a first light source configured to direct a first type of light to the inspection region, the first light source defining a first axis, the first axis and the camera axis defining a first angle; and a second light source configured to direct a second type of light to the inspection region, the second type of light different than the first type of light, the second light source defining a second axis, the second axis and the camera axis defining a second angle different than the first angle.

9. The inspection assembly of claim 8, wherein the first type of light is white light, and wherein the second type of light is ultraviolet light.

10. The inspection assembly of claim 9, wherein the second angle is greater than the first angle.11 . The inspection assembly of claim 8, further comprising a third light source configured to direct the first type of light to the inspection region, wherein the third light source is oriented along the camera axis.

12. The inspection assembly of claim 11, wherein the first type of light is white light.

13. The inspection assembly of claim 8, wherein the intensity of the first light source is adjustable, and the intensity of the second light source is adjustable.

14. The inspection assembly of claim 8, wherein the first angle is adjustable by pivoting the first light source, and wherein the second angle is adjustable by pivoting the second light source.

15. A method of inspecting ceramic bearing rollers with an inspection assembly, the method comprising: providing the inspection assembly including a camera, a support block configured to support the ceramic bearing rollers, a first light source, a second light source, and a control system, the camera defining a camera axis, providing a first roller including a first geometry and defining a longitudinal axis; loading the first roller into the support block; determining an operational orientation of the first roller with the control system; orienting the first roller with the support block such that the longitudinal axis is perpendicular to the camera axis; illuminating a first surface of the first roller with the first light source or the second light source; capturing an image of the first roller with the camera; and removing the first roller from the support block.

16. The method of claim 15, wherein the first light source emits a first type of light, and wherein the second light source emits a second type of light, the second type of light different than the first type of light.

17. The method of claim 16, wherein the first type of light is white light, and wherein the second type of light is ultraviolet light.

18. The method of claim 15, further comprising providing a second roller including a second geometry and defining a second longitudinal axis, the second geometry different than the first geometry, loading the second roller into the support block, orienting the second roller with the support block such that the longitudinal axis is perpendicular to the camera axis, illuminating a second surface of the second roller with the first light source or the second light source, capturing an image of the second roller with the camera, and removing the second roller from the support block.

19. The method of claim 18, wherein the first roller is a cylindrical roller, the second roller is a tapered roller, and wherein the orienting the second roller such that the longitudinal axis is perpendicular to the camera axis includes pivoting the support block.

20. The method of claim 15, further comprising detecting defects on the first surface with the control system and displaying the defects on a user interface.

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