3D Scan Path Programming for Metrology Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machine vision inspection systems lack simplicity and robustness in operation and programming for high precision chromatic range sensors, making it difficult for unskilled users to create reliable part programs that integrate both machine vision and chromatic range sensor components, and achieve high throughput.
Innovation Solution
A metrology system with a user-friendly interface that allows users to define and execute precise 3D scan paths using a combination of less precise and more precise Z-height sensing systems, enabling automatic adjustment of the sensor height to maintain measurements within the measuring range of the precise Z-height sensor, thereby facilitating reliable and efficient surface Z-height measurements across varying workpiece surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a precise Z-height sensing system with a narrow measuring range is used, then measurement precision is improved, but the device complexity and programming difficulty increase
Solution Approach 1:
A less precise Z-height sensing system acts as an intermediary to provide preliminary surface height measurements. These preliminary measurements guide the positioning of the precise Z-height sensor, enabling it to operate within its narrow measuring range while simplifying the overall programming process through automatic path generation.
Solution Approach 2:
The less precise Z-height sensor performs preliminary scanning to map the workpiece surface topography before the precise Z-height sensor executes detailed measurements. This preliminary action eliminates the need for complex manual programming of the precise sensor's positioning, as the scan path is automatically generated based on the preliminary surface data.
2Measurement precision
If a single precise Z-height sensor is used, then measurement accuracy is improved, but the productivity decreases due to frequent height adjustments
Solution Approach 1:
The measurement process is segmented into two stages: a preliminary scanning stage using a less precise sensor to map the surface, and a detailed measurement stage using the precise sensor. This segmentation allows the precise sensor to maintain optimal positioning throughout the scan, eliminating frequent height adjustments and maintaining high productivity.
Solution Approach 2:
The preliminary surface mapping by the less precise sensor enables the system to pre-calculate the optimal scan path for the precise sensor. This preliminary action ensures that the precise sensor operates continuously within its measuring range without interruptions for height adjustments, thereby maintaining high scan throughput.
3Measurement precision
If manual video tool set-up is used, then measurement precision can be achieved, but the ease of operation decreases for unskilled users
Solution Approach 1:
The system performs self-service by automatically generating the precise 3D scan path based on preliminary surface measurements. The automatic path generation algorithm processes the preliminary data and creates optimized measurement paths without requiring manual intervention, making the system easy to operate while maintaining measurement precision.
Solution Approach 2:
The preliminary scanning and surface mapping automatically prepare the data needed for precise measurement path generation. This preliminary action eliminates the need for unskilled users to manually configure complex measurement parameters, as the system automatically processes the preliminary data to generate accurate measurement paths.
4Adaptability or versatility
If learn mode programming is used, then adaptability to specific workpieces is improved, but the loss of time increases due to programming and debugging
Solution Approach 1:
The system performs preliminary surface mapping that automatically generates the foundation for workpiece-specific inspection paths. This preliminary action significantly reduces the time required for learn mode programming, as the system automatically adapts to the specific workpiece geometry without requiring extensive manual programming or debugging by the user.
Solution Approach 2:
The automatic scan path generation algorithm performs self-service by processing preliminary surface data and creating optimized inspection paths specific to each workpiece. This eliminates the need for manual programming and extensive debugging, reducing the time loss while maintaining full adaptability to different workpiece configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables relatively unskilled users to create reliable high-throughput part programs for precise surface Z-height measurements, improving measurement accuracy and reducing programming and debugging time, while maintaining predictable scan speed and robustness.
Implementation Method 1
chromatic aberration techniques are utilized for high precision distance sensing metrology
Data Source
AI summary
A method for programming a three-dimensional (3D) workpiece scan path for a metrology system comprising a 3D motion control system, a first type of Z-height sensing system, and a second type of Z-height sensing system that provides less precise surface Z-height measurements over a broader Z-height measuring range. The method comprises: placing a representative workpiece on a stage of the metrology system, defining at least a first workpiece scan path segment for the representative workpiece, determining preliminary actual surface Z-height measurements along the first workpiece scan path segment, and determining a precise 3D scan path for moving the first type of Z-height sensing system to perform precise surface Z-height measurements. The precise 3D scan path is based on the determined preliminary actual surface Z-height measurements. The precise 3D scan path may be used for performing precise surface Z-height measurements or stored to be used in an inspection program.