CAD-to-Part Image Alignment for Automated Deviation Inspection
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Solution Overview
Problem
Conventional optical comparators for checking part compliance with CAD drawings suffer from low accuracy and operator dependence due to manual alignment processes and suboptimal orientation and magnification of overlays.
Innovation Solution
A system and method for aligning a CAD drawing with multiple images of a part using an imaging device, memory module, and processing module to perform iterative alignment adjustments, determining alignment adjustments between control sections, and providing deviation indications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment technique is used in conventional optical comparators, then the operator can perform the alignment process, but the accuracy and reliability of the comparison result deteriorates due to operator dependence and skill variability
Solution Approach 1:
The patent replaces the manual mechanical alignment process with an automated computer vision system that uses image processing algorithms to automatically align the overlay with the part image. The system captures images of the part and overlay, processes them computationally, and automatically determines alignment without human intervention, thereby eliminating operator dependence while maintaining high precision.
Solution Approach 2:
The system performs self-alignment by automatically processing the images and determining the correct positioning of the overlay relative to the part. The computer vision algorithm independently completes the alignment task without requiring external human input or adjustment, making the system self-sufficient and eliminating variability introduced by different operators.
2Adaptability or versatility
If overlay is used in conventional optical comparators, then the geometric definition can be displayed, but the orientation and magnification level cannot be ideally suited to the comparison process
Solution Approach 1:
The system dynamically adjusts the orientation and magnification of the overlay to match the optimal viewing angles for different features being inspected. Rather than using a fixed overlay, the computer-generated overlay can be rotated and scaled in real-time based on the specific comparison task, allowing the system to adapt to various inspection requirements and maintain ideal orientation for accurate measurement.
3Measurement precision
If automated alignment system is implemented, then accuracy and productivity are improved, but the device complexity increases
Solution Approach 1:
The system uses digital copies of the geometric definitions from CAD files to generate overlays, replacing the need for physical transparencies or printed overlays. This digital copying approach simplifies the hardware requirements while enabling automated processing, as the overlay can be easily manipulated and adjusted through software without requiring complex mechanical adjustment mechanisms.
Data Source
AI summary
A system is provided for alignment and comparison of a CAD drawing that includes one or more control sections with multiple images of a part. Each of the multiple images corresponds to a portion of the part and a combination of the multiple images provides a representation of the part as a whole. The system comprises an imaging device for acquiring the multiple images, a memory module for storing the multiple images and associated imaging position data, and a processing module configured to perform an initial alignment of the CAD drawing with the multiple images of the part, determine an initial total alignment adjustment based on the initial alignment and perform one or more alignment iterations until a termination condition is satisfied. The system further comprises an output device for providing a user with an indication of a deviation, based on the alignment between the CAD drawing and the part.