Automated Part Measurement Using Multi-Sensor Depth Data Alignment
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Solution Overview
Problem
Current part inspection methods are labor-intensive, time-consuming, and prone to human error, especially when measuring large or complex parts, and often require multiple tools and precise calibration.
Innovation Solution
A system and method using depth data from a plurality of sensors to automate the measurement of parts, involving the detection of planes corresponding to monument faces, rotational and translational alignment, and transformation into a common coordinate system to determine accurate part measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used with multiple tools and calibration, then measurement accuracy can be maintained, but inspection time and labor intensity increase significantly
Solution Approach 1:
The patent replaces manual mechanical measurement tools (calipers, tape measures) with an automated depth sensing system that uses optical or electromagnetic fields to capture depth data. Multiple sensors arrayed across the part surface simultaneously acquire measurement data, eliminating the need for sequential manual measurements while maintaining accuracy through computational processing of the depth data.
Solution Approach 2:
The system performs preliminary calibration by detecting planes corresponding to monument faces before actual part measurement. This preliminary action establishes a reference coordinate system and alignment transformations, so that when measurement begins, the system is already prepared to accurately map sensor data to the part geometry without requiring repeated calibration during inspection.
2Measurement precision
If multiple sensors are used to capture comprehensive depth data, then measurement accuracy and coverage improve, but data alignment complexity increases
Solution Approach 1:
The patent introduces monument faces as intermediary reference elements that mediate between multiple sensors and the target part. Each sensor captures depth data of both the part and the monument, and the known geometry of the monument faces serves as a common reference frame. This intermediary structure provides fixed reference planes that all sensors can independently align to, simplifying the fusion of multi-sensor data by providing a stable coordinate system basis.
Solution Approach 2:
The system transforms raw depth data from multiple sensors into a common coordinate system by applying rotational and translational transformations. The alignment process changes the parameters (orientation and position) of each sensor's coordinate system to match the monument-defined reference frame, enabling accurate fusion of depth data from all sensors while accounting for their different spatial orientations.
3Productivity
If automated depth sensing is implemented, then inspection speed and throughput increase, but system complexity and calibration requirements increase
Solution Approach 1:
The system performs self-calibration by automatically detecting the monument faces and computing the necessary rotational and translational transformations without requiring manual intervention. The automated processing pipeline independently aligns all sensor data to the common coordinate system defined by the monument, eliminating the need for operators to perform complex calibration procedures while maintaining measurement accuracy.
Data Source
AI summary
A method of obtaining a measurement of a part using depth data from a plurality of sensors comprises obtaining first depth data of a monument and a part from a first sensor and second depth data of the monument and the part from a second sensor. A plurality of planes is detected in the first depth data and the second depth data. Each plane of the plurality of planes corresponds to a corresponding face on the monument. The method comprises performing a rotational alignment of the plurality of planes. The method further comprises performing a translational alignment of the rotationally aligned plurality of planes. One or more transformations are determined that align the first depth data and the second depth data to a common coordinate system based upon the rotational alignment and the translational alignment. A measurement of the part is determined based upon aligned depth data.