Patent Application
20210097674
The present disclosure relates to objectively identifying and correcting surface irregularities in objects, and more particularly, in body-in-white and vehicle-on-wheel surfaces.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Galvanizing steel, which generally involves applying a thin coating of zinc to the steel to protect against corrosion, offers a wide array of advantages for use in body-in-white (“BIW”) and vehicle-on-wheel (“VOW”) applications. More specifically, galvanized steel has a low initial cost, provides a sacrificial coating, is resistant to damage, and increases durability while offering lower maintenance costs over non-galvanized steel. Galvanizing BIW and VOW surfaces is resultantly prevalent in the automotive industry. After galvanization, irregularities are subjectively identified (e.g., by eye or touch) and perceived irregularities are then corrected.
And in general, carbon fibers and alloys such as steel, nickel alloys, aluminum alloys, also have their surfaces subjectively identified for irregularities, which are then corrected when an irregularity is identified. These issues related to identifying and accurately correcting surface irregularities in surfaces of an object are addressed by the present disclosure.
According to one form of the present disclosure, a system for detecting and correcting at least one irregularity of at least one surface of an object includes a conveyor configured to transport an object through an inspection station and a finishing station. The inspection station includes a plurality of cameras configured to detect at least an irregularity of the surfaces of the object, and the plurality of cameras photograph the surfaces of the objects under a light having a wavelength of greater than or equal to about 380 nm to less than or equal to about 740 nm. The finishing station includes a robot, and the robot includes a light source configured to emit a light having a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm, a camera, and an abrasive tool configured to correct any detected irregularity.
In a variation, the plurality of cameras photograph the surface under a light having a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm. In yet other such variations, the light source of the robot is configured to emit a light having a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm.
In a further variation, a tool station is positioned adjacent to the robot.
In another variation, the object is transported through the inspection station at a substantially constant speed. In other such variations, the object is transported through the finishing station at a substantially constant speed.
In yet another variation, the finishing station further comprises a display configured to display any detected irregularity of.
According to another form, a method for detecting and correcting at least one irregularity of at least one surface of an object includes photographing the surfaces of the object under a light having a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm to detect the irregularity while the object is transported through an inspection station. Corresponding coordinates of any irregularity detected are mapped to a set of coordinates corresponding to the object. Any detected irregularity are corrected in a finishing station by applying an abrasive tool to a location specified by the mapped corresponding coordinates.
In a variation, after correcting any irregularity, the irregularity corrected is illuminated at a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm.
In another variation, the light has a wavelength of greater than or equal to about 520 nm to less than or equal to about 560. In other such variations, after correcting any irregularity, the irregularity corrected is illuminated at a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm.
In a further variation, the location specified by the mapped corresponding coordinates is displayed.
In yet a further variation, the object is transported through the inspection station at a substantially constant speed. In other such variations, the object is transported through the finishing station at a substantially constant speed.
According to a further form, a method for detecting and correcting at least one irregularity of at least one surface of an object includes identifying any irregularity while the object is transported through an inspection station by photographing the at least one surface of the object to be corrected under a light having a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm. Any irregularity detected is displayed. Any irregularity is corrected in a finishing station by applying an abrasive tool to a location corresponding to the area on the object where the irregularity detected is displayed.
In a variation, after correcting any irregularities, the area corresponding to the detected irregularity is illuminated at a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm.
In another variation, the light has a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm. In other such variations, after correcting any irregularity detected, the area corresponding to the detected irregularity is illuminated at a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm.
In a further variation, the object is transported through the inspection station at a substantially constant speed. In other such variations, the object is transported through the finishing station at a substantially constant speed.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to
Referring to
The inspection station 100 further includes at least one camera 106 having at least a light source positioned on a first side 108 of the inspection station 100 and at least one other camera 110 having at least a light source positioned on a second side 112 of the inspection station 100. The light sources of the cameras 106 and 110 emit a light having a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm. According to a variation, the light sources of the cameras 106 and 110 emit a light having a wavelength of greater than or equal to about 380 nm to less than or equal to about 740 nm. According to a variation, the light sources of the cameras 106 and 110 emit a light having a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm (i.e., green light). The cameras 106 and 110 are configured to capture images of the surfaces or portions of surfaces (referred to herein simply as “surfaces”) of the object 10 while the light sources are directing light to the surfaces, such as surfaces 18, 20, shown in
Any camera(s) that is capable of capturing images of surfaces while the object 10 is illuminated under the aforementioned wavelengths is suitable such as the cameras 106 and 110. Exemplary cameras include image colorimeters and photometers, commercially available from Radiant Vision Systems, LLC. The cameras 106 and 110 are movable (in rotation and translation, with an unlimited number of degrees of freedom (DOF)) such that all features, including corners, pockets or recesses, curved surfaces, flat surfaces, and all surface profile geometries, of the object 10 can be captured. In a variation, the camera 106 can be secured to a movable robot or robot arm to allow the camera 106 to more accurately and comprehensively capture all of the surfaces of the object 10. In a variation, multiple cameras work together to capture all of the surfaces of the object 10 and each can be secured to a respective robot or robot arm.
In a variation, at least a ceiling light 114 is positioned in the inspection station 100 to provide additional light as necessary to illuminate the surfaces for the cameras 106/110. Any ceiling lights, such as the ceiling light 114, may emit light at a wavelength at or substantially similar to the wavelength of the sources of light emitted by the cameras to provide additional light if warranted.
In a variation, the cameras (such as cameras 106 and 110) are configured to detect light from the light sources reflected and/or refracted from the surfaces of the object, e.g., by emitting electromagnetic waves that interact with the surfaces of the object 10. Based on these reflections or refractions of the light and the refractive index of the surfaces of the object 10, the camera 106 and 110 can detect surface irregularities on the surfaces of the object 10 and capture images of the detected surface irregularities. One example of a surface irregularity is scratch 19 (
As described in greater detail below, the cameras (such as cameras 106 and 110) may be configured to communicate the associated coordinates of the irregularities detected on surfaces of the object 10 relative to a coordinate system to a controller 118, where images captured showing irregularities are shown on a display.
Referring to
Each of the robots (such as the first robot 202 and the second robot 206) includes an abrasive tool 214 and a light source 216. The light source 216 includes a camera, and any camera that is capable of capturing images of surfaces while the object 10 is illuminated under the wavelengths described below is suitable as the camera of the light source 216. Exemplary cameras include image colorimeters and photometers, commercially available from Radiant Vision Systems, LLC. The light source 216 is configured to emit a light having a wavelength of greater than or equal to about 400 nm to less than or equal to about 565 nm. According to a variation, the light source 216 emits a light having a wavelength of greater than or equal to about 380 nm to less than or equal to about 740 nm. According to a variation, the light source 216 is configured to emit a light having a wavelength of greater than or equal to about 520 nm to less than or equal to about 560 nm. The robots 202, 206 move such that the abrasive tools 214 can reach the surfaces of the object 10 and a respective tool station 210, 212. The robots 202, 206 are also movable such that the light sources 216 can illuminate the surfaces of the object 10. According to a variation, the abrasive tools 214 and the light sources 216 may reside on a single arm of each robot 202, 206, such as a robot arm 218. According to another variation, the abrasive tools 214 and the light sources 216 may reside on separate arms of a respective robots 202, 206.
According to a variation, the finishing station includes at least one display 220 for displaying any irregularity identified. The display 220 may display the irregularity in a grid like manner, such as shown in
In operation, in the finishing station 200, a robot (such as the first robot 202) identifies and selects an abrasive, such as sandpaper, polishing stones, grinder pads, grinder stones, and buffing stones, among others, for attachment to the abrasive tool 214 from a respective tool station (such as the first tool station 212) that is tailored to correct the irregularity detected. The robot then moves the abrasive tool 214 to the irregularity of the surface of the object 10, applies a predetermined force to the surface via the abrasive tool 214, and abrades the irregularity for a predetermined amount of time (referred to herein as a “first abrasion”). While the robot abrades the irregularity, the light source 216 illuminates the irregularity and captures photographs of the irregularity. The captured photos are visually inspected by an operator or data corresponding to the captured photos are digitally analyzed to determine whether irregularities are visible, and, if so, whether further abrasion is warranted. If not, the robot again applies the abrasive tool 214 to the irregularity at a predetermined force for a predetermined amount of time (referred to herein as a “second abrasion”). The force and time in the second abrasion may be the same or different from the first abrasion, depending on the changing nature of the irregularity detected after the initial abrasion. If warranted, a third abrasion, a fourth abrasion, and additional abrasions, may occur. If, after a predetermined number of attempts at correcting the irregularity do not satisfactorily correct the irregularity, the object 10 may exit the production cycle for further processing.
Referring to
According to a variation, the frequency of irregularities may be logged into a database. In this fashion, it can be determined how often a particular source delivers objects having irregularities.
According to a variation, the program controlling the behavior of any robot (such as the first robot 202) can be overwritten with a new or supplemental program to meet any particular demand.
Although the terms first, second, third, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections, should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer and/or section, from another element, component, region, layer and/or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section, could be termed a second element, component, region, layer or section without departing from the teachings of the example forms. Furthermore, an element, component, region, layer or section may be termed a “second” element, component, region, layer or section, without the need for an element, component, region, layer or section termed a “first” element, component, region, layer or section.
Spacially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” “adjacent,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above or below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice; material, manufacturing, and assembly tolerances; and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
The terminology used herein is for the purpose of describing particular example forms only and is not intended to be limiting. The singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
