U.S. patent application number 13/524028 was filed with the patent office on 2013-08-22 for coordinate measurement machines with removable accessories.
This patent application is currently assigned to FARO TECHNOLOGIES, INC.. The applicant listed for this patent is Robert E. Bridges, Clark H. Briggs, John M. Hoffer, JR.. Invention is credited to Robert E. Bridges, Clark H. Briggs, John M. Hoffer, JR..
Application Number | 20130212889 13/524028 |
Document ID | / |
Family ID | 48134758 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130212889 |
Kind Code |
A9 |
Bridges; Robert E. ; et
al. |
August 22, 2013 |
COORDINATE MEASUREMENT MACHINES WITH REMOVABLE ACCESSORIES
Abstract
A portable articulated arm coordinate measuring machine for
measuring the coordinates of an object in space is provided. The
AACMM includes a base and an arm portion having an opposed first
and second ends. The arm portion including a plurality of connected
arm segments that each includes at least one position transducer
for producing a position signal. An electronic circuit is provided
that receives the position signal from the at least one position
transducer and provides data corresponding to a position of the
measurement device. A noncontact three-dimensional measuring device
is coupled to the first end, the device having an electromagnetic
radiation transmitter and is configured to determine a distance to
an object based at least in part on the speed of light in air. A
processor is configured to determine the three-dimensional
coordinates of a point on the object in response to receiving the
position signals and the distance to the object.
Inventors: |
Bridges; Robert E.; (Kennett
Square, PA) ; Briggs; Clark H.; (DeLand, FL) ;
Hoffer, JR.; John M.; (Bel Air, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bridges; Robert E.
Briggs; Clark H.
Hoffer, JR.; John M. |
Kennett Square
DeLand
Bel Air |
PA
FL
MD |
US
US
US |
|
|
Assignee: |
FARO TECHNOLOGIES, INC.
Lake Mary
FL
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130097882 A1 |
April 25, 2013 |
|
|
Family ID: |
48134758 |
Appl. No.: |
13/524028 |
Filed: |
June 15, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13006507 |
Jan 14, 2011 |
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13524028 |
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13493639 |
Jun 11, 2012 |
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13006507 |
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13006507 |
Jan 14, 2011 |
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13493639 |
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61296555 |
Jan 20, 2010 |
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61355279 |
Jun 16, 2010 |
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61351347 |
Jun 4, 2010 |
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61296555 |
Jan 20, 2010 |
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61355279 |
Jun 16, 2010 |
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61351347 |
Jun 4, 2010 |
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Current U.S.
Class: |
33/503 |
Current CPC
Class: |
G05B 19/401 20130101;
G01B 21/047 20130101; G05B 2219/45061 20130101; G01B 11/005
20130101; G05B 2219/37193 20130101; G01B 2210/58 20130101; G01B
5/008 20130101; G01B 5/012 20130101; G05B 2219/40233 20130101 |
Class at
Publication: |
33/503 |
International
Class: |
G01B 11/00 20060101
G01B011/00 |
Claims
1. A portable articulated arm coordinate measuring machine (AACMM)
for measuring the coordinates of an object in space, comprising: a
base; a manually positionable arm portion having an opposed first
end and second end, the arm portion being rotationally coupled to
the base, the arm portion including a plurality of connected arm
segments, each arm segment including at least one position
transducer for producing a position signal; an electronic circuit
configured to receive the position signal from the at least one
position transducer; a probe end coupled to the first end; a
noncontact three-dimensional measurement device coupled to the
probe end, the noncontact three-dimensional measurement device
having an electromagnetic radiation transmitter, the noncontact
three-dimensional measurement device configured to determine a
distance to an object based at least in part on the speed of light
in air; and a processor electrically coupled to the electronic
circuit, the processor configured to determine the
three-dimensional coordinates of a point on the object in response
to receiving the position signals from the electronic circuit and
in response to receiving the distance to the object from the
noncontact three-dimensional measurement device.
2. The AACMM of claim 1 wherein the noncontact three-dimensional
measurement device is an absolute interferometer device.
3. The AACMM of claim 2 wherein the absolute interferometer
includes a camera adjacent the transmitter.
4. The AACMM of claim 1 wherein the noncontact three-dimensional
measurement device is a phase-based ADM device.
5. The AACMM of claim 1 wherein the noncontact three-dimensional
measurement device is a pulsed time of flight ADM device.
6. The AACMM of claim 1 wherein the noncontact three-dimensional
measurement device is removably coupled to the probe end.
7. The AACMM of claim 1 wherein the electromagnetic radiation
transmitter is a laser.
8. The AACMM of claim 1 further comprising a contact measurement
device coupled to the probe end.
9. The AACMM of claim 1 wherein the noncontact three-dimensional
measurement device is removably coupled to the probe end.
10. A method of operating a portable articulated arm coordinate
measuring machine for measuring three-dimensional coordinates of an
object in space, comprising: providing a manually positionable arm
portion having an opposed first end and second end, the arm portion
including a plurality of connected arm segments, each arm segment
including at least one position transducer for producing a position
signal; receiving at an electronic circuit the position signals
from the transducers; providing a noncontact three-dimensional
measurement device having a controller electrically coupled to the
electronic circuit, the three-dimensional measurement device having
an electromagnetic radiation transmitter and a sensor; transmitting
an electromagnetic radiation from the three-dimensional measurement
device onto the object; receiving a reflected electromagnetic
radiation with the sensor; determining a distance to the object
from the reflected electromagnetic radiation received by the
sensor, wherein the distance is based at least in part on the speed
of light in air and on a time for the electromagnetic radiation to
travel from the electromagnetic radiation transmitter to the object
and return to the sensor; and determining the three-dimensional
coordinates of a point on the object based at least in part on the
position signals received from the transducers and on the
determined distance.
11. The method of claim 10 wherein, in the step of providing a
noncontact three-dimensional measurement device, the noncontact
three-dimensional measurement device is an absolute interferometer
device.
12. The method of claim 11 wherein, in the step of providing a
noncontact three-dimensional measurement device, the absolute
interferometer includes a camera adjacent the transmitter.
13. The method of claim 10 wherein, in the step of providing a
noncontact three-dimensional measurement device, the noncontact
three-dimensional measurement device is a phase-based ADM
device.
14. The method of claim 10 wherein, in the step of providing a
noncontact three-dimensional measurement device, the noncontact
three-dimensional measurement device is a pulsed time of flight ADM
device.
15. The method of claim 10 wherein, in the step of providing a
noncontact three-dimensional measurement device, the noncontact
three-dimensional measurement device is removably coupled to the
first end.
16. The method of claim 10 further comprising: providing a probe
end coupled to the first end; and removably coupling the noncontact
three-dimensional measurement device to the probe end.
17. The method of claim 16 wherein: in the step of providing a
probe end, the probe end further includes a fastener and a first
electrical connector electrically coupled to the electronic
circuit; and, in the step of providing a noncontact
three-dimensional measurement device, the noncontact
three-dimensional measurement device further has a coupler and a
second electrical connector electrically coupled to the
controller.
18. The method of claim 17 further comprising: mechanically
coupling the three-dimensional measurement device to the probe end
with the coupler and the fastener; and electrically coupling the
first electrical connector to the second electrical connector.
19. The method of claim 10 wherein, in the step of providing a
noncontact three-dimensional measurement device, the
electromagnetic radiation transmitter is a laser.
20. The method of claim 10 further comprising providing a contact
measurement device coupled to the first end.
21. A portable articulated arm coordinate measuring machine (AACMM)
for measuring three-dimensional coordinates of an object in space,
comprising: a base; a manually positionable arm portion having an
opposed first end and second end, the arm portion being
rotationally coupled to the base, the arm portion including a
plurality of connected arm segments, each arm segment including at
least one position transducer for producing a position signal; an
electronic circuit which receives the position signal from the at
least one position transducer; a probe end disposed between the
measurement device and the first end, the probe end having an
interface on one side; and a noncontact three-dimensional
measurement device removably coupled to the interface, the
noncontact three-dimensional measuring device having a light source
and an optical receiver, the noncontact three-dimensional measuring
device configured to determine a distance to a point on the object
based at least in part on a speed of light in air and on a time for
light from the light source to travel from the light source to the
object and return to the optical receiver; and a processor
electrically coupled to the electronic circuit, the processor
configured to determine the three-dimensional coordinates of the
point on the object based at least in part on the position signals
received from the transducers and on the determined distance.
22. The AACMM of claim 21 wherein the noncontact three-dimensional
measurement device is an absolute interferometer device.
23. The AACMM of claim 22 wherein the absolute interferometer
includes a camera adjacent the transmitter.
24. The AACMM of claim 21 wherein the noncontact three-dimensional
measurement device is a phase-based ADM device.
25. The AACMM of claim 21 wherein the noncontact three-dimensional
measurement device is a pulsed time of flight ADM device.
26. The AACMM of claim 21 further including a contact probe coupled
to probe end.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
patent application Ser. No. 13/006,507 filed Jan. 14, 2011, and
claims the benefit of provisional application number 61/296,555
filed Jan. 20, 2010, provisional application number 61/355,279
filed Jun. 16, 2010, and provisional application number 61/351,347
filed on Jun. 4, 2010, the contents of which are hereby
incorporated by reference in their entirety.
BACKGROUND
[0002] The present disclosure relates to a coordinate measuring
machine, and more particularly to a portable articulated arm
coordinate measuring machine having a connector on a probe end of
the coordinate measuring machine that allows accessory devices
which use transit time of flight for non-contact three dimensional
measurement to be connected to the coordinate measuring
machine.
[0003] Portable articulated arm coordinate measuring machines
(AACMMs) have found widespread use in the manufacturing or
production of parts where there is a need to rapidly and accurately
verify the dimensions of the part during various stages of the
manufacturing or production (e.g., machining) of the part. Portable
AACMMs represent a vast improvement over known stationary or fixed,
cost-intensive and relatively difficult to use measurement
installations, particularly in the amount of time it takes to
perform dimensional measurements of relatively complex parts.
Typically, a user of a portable AACMM simply guides a probe along
the surface of the part or object to be measured. The measurement
data are then recorded and provided to the user. In some cases, the
data are provided to the user in visual form, for example,
three-dimensional (3-D) form on a computer screen. In other cases,
the data are provided to the user in numeric form, for example when
measuring the diameter of a hole, the text "Diameter=1.0034" is
displayed on a computer screen.
[0004] An example of a prior art portable articulated arm CMM is
disclosed in commonly assigned U.S. Pat. No. 5,402,582 ('582),
which is incorporated herein by reference in its entirety. The '582
patent discloses a 3-D measuring system comprised of a
manually-operated articulated arm CMM having a support base on one
end and a measurement probe at the other end. Commonly assigned
U.S. Pat. No. 5,611,147 ('147), which is incorporated herein by
reference in its entirety, discloses a similar articulated arm CMM.
In the '147 patent, the articulated arm CMM includes a number of
features including an additional rotational axis at the probe end,
thereby providing for an arm with either a two-two-two or a
two-two-three axis configuration (the latter case being a seven
axis arm).
[0005] Three-dimensional surfaces may be measured using non-contact
techniques as well. One type of non-contact device, sometimes
referred to as a laser line probe, emits a laser light either on a
spot, or along a line. A imaging device, such as a charge-coupled
device (CCD) for example, is positioned adjacent the laser to
capture an image of the reflected light from the surface. The
surface of the object being measured causes a diffuse reflection.
The image on the sensor will change as the distance between the
sensor and the surface changes. By knowing the relationship between
the imaging sensor and the laser and the position of the laser
image on the sensor, triangulation methods may be used to measure
points on the surface.
[0006] While existing CMMs are suitable for their intended
purposes, what is needed is a portable AACMM that has certain
features of embodiments of the present invention.
SUMMARY OF THE INVENTION
[0007] In accordance with one embodiment of the invention, a
portable articulated arm coordinate measuring machine (AACMM) for
measuring the coordinates of an object in space is provided. The
AACMM includes a base and a manually positionable arm portion
having an opposed first end and second end. The arm portion being
rotationally coupled to the base, the arm portion including a
plurality of connected arm segments, each arm segment including at
least one position transducer for producing a position signal. An
electronic circuit is configured to receive the position signal
from the at least one position transducer. A probe end is coupled
to the first end. A noncontact three-dimensional measurement device
is coupled to the probe end. The noncontact three-dimensional
measurement device having an electromagnetic radiation transmitter,
the noncontact three-dimensional measurement device configured to
determine a distance to an object based at least in part on the
speed of light in air. A processor is electrically coupled to the
electronic circuit, the processor configured to determine the
three-dimensional coordinates of a point on the object in response
to receiving the position signals from the electronic circuit and
in response to receiving the distance to the object from the
noncontact three-dimensional measurement device.
[0008] In accordance with one embodiment of the invention, a method
of operating a portable articulated arm coordinate measuring
machine for measuring three-dimensional coordinates of an object in
space is provided. The method includes the step of providing a
manually positionable arm portion having an opposed first end and
second end, the arm portion including a plurality of connected arm
segments, each arm segment including at least one position
transducer for producing a position signal. An electronic circuit
receives the position signals from the transducers. A noncontact
three-dimensional measurement device is provided having a
controller electrically coupled to the electronic circuit, the
three-dimensional measurement device having an electromagnetic
radiation transmitter and a sensor. An electromagnetic radiation is
transmitted from the three-dimensional measurement device onto the
object. A reflected electromagnetic radiation is received with the
sensor. A distance to the object is determined from the reflected
electromagnetic radiation received by the sensor, wherein the
distance is based at least in part on the speed of light in air and
on a time for the electromagnetic radiation to travel from the
electromagnetic radiation transmitter to the object and return to
the sensor.
[0009] In accordance with another embodiment of the invention,
another portable articulated arm coordinate measuring machine
(AACMM) for measuring three-dimensional coordinates of an object in
space is provided. The AACMM includes a base and a manually
positionable arm portion having an opposed first end and second
end. The arm portion being rotationally coupled to the base, the
arm portion including a plurality of connected arm segments, each
arm segment including at least one position transducer for
producing a position signal. An electronic circuit is provided
which receives the position signal from the at least one position
transducer. A probe end is disposed between the measurement device
and the first end, the probe end having an interface on one side. A
noncontact three-dimensional measurement device is removably
coupled to the interface, the noncontact three-dimensional
measuring device having a light source and an optical receiver. The
noncontact three-dimensional measuring device configured to
determine a distance to a point on the object based at least in
part on a speed of light in air and on a time for light from the
light source to travel from the light source to the object and
return to the optical receiver. A processor is electrically coupled
to the electronic circuit, the processor configured to determine
the three-dimensional coordinates of the point on the object based
at least in part on the position signals received from the
transducers and on the determined distance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Referring now to the drawings, exemplary embodiments are
shown which should not be construed to be limiting regarding the
entire scope of the disclosure, and wherein the elements are
numbered alike in several FIGURES:
[0011] FIG. 1, including FIGS. 1A and 1B, are perspective views of
a portable articulated arm coordinate measuring machine (AACMM)
having embodiments of various aspects of the present invention
therewithin;
[0012] FIG. 2, including FIGS. 2A-2D taken together, is a block
diagram of electronics utilized as part of the AACMM of FIG. 1 in
accordance with an embodiment;
[0013] FIG. 3, including FIGS. 3A and 3B taken together, is a block
diagram describing detailed features of the electronic data
processing system of FIG. 2 in accordance with an embodiment;
[0014] FIG. 4 is an isometric view of the probe end of the AACMM of
FIG. 1;
[0015] FIG. 5 is a side view of the probe end of FIG. 4 with the
handle being coupled thereto;
[0016] FIG. 6 is a side view of the probe end of FIG. 4 with the
handle attached;
[0017] FIG. 7 is an enlarged partial side view of the interface
portion of the probe end of FIG. 6;
[0018] FIG. 8 is another enlarged partial side view of the
interface portion of the probe end of FIG. 5;
[0019] FIG. 9 is an isometric view partially in section of the
handle of FIG. 4;
[0020] FIG. 10 is an isometric view of the probe end of the AACMM
of FIG. 1 with a noncontact distance measurement device
attached;
[0021] FIG. 11 is a schematic view of an embodiment wherein the
device of FIG. 10 is an interferometer system;
[0022] FIG. 12 is a schematic view of an embodiment wherein the
device of FIG. 10 is an absolute distance meter system;
[0023] FIG. 13 is a schematic view of an embodiment wherein the
device of FIG. 10 is a focusing type distance meter; and
[0024] FIG. 14 is a schematic view of an embodiment wherein the
device of FIG. 10 is a contrast focusing type of distance
meter.
DETAILED DESCRIPTION
[0025] Portable articulated arm coordinate measuring machines
("AACMM") are used in a variety of applications to obtain
measurements of objects. Embodiments of the present invention
provide advantages in allowing an operator to easily and quickly
couple accessory devices to a probe end of the AACMM that use
structured light to provide for the non-contact measurement of a
three-dimensional object. Embodiments of the present invention
provide further advantages in providing for communicating data
representing a distance to an object measured by the accessory.
Embodiments of the present invention provide still further
advantages in providing power and data communications to a
removable accessory without having external connections or
wiring.
[0026] FIGS. 1A and 1B illustrate, in perspective, an AACMM 100
according to various embodiments of the present invention, an
articulated arm being one type of coordinate measuring machine. As
shown in FIGS. 1A and 1B, the exemplary AACMM 100 may comprise a
six or seven axis articulated measurement device having a probe end
401 (FIG. 4) that includes a measurement probe housing 102 coupled
to an arm portion 104 of the AACMM 100 at one end. The arm portion
104 comprises a first arm segment 106 coupled to a second arm
segment 108 by a first grouping of bearing cartridges 110 (e.g.,
two bearing cartridges). A second grouping of bearing cartridges
112 (e.g., two bearing cartridges) couples the second arm segment
108 to the measurement probe housing 102. A third grouping of
bearing cartridges 114 (e.g., three bearing cartridges) couples the
first arm segment 106 to a base 116 located at the other end of the
arm portion 104 of the AACMM 100. Each grouping of bearing
cartridges 110, 112, 114 provides for multiple axes of articulated
movement. Also, the probe end 401 may include a measurement probe
housing 102 that comprises the shaft of an axis of rotation for the
AACMM 100 (e.g., a cartridge containing an encoder system that
determines movement of the measurement device, for example a probe
118, in an axis of rotation for the AACMM 100). In this embodiment,
the probe end 401 may rotate about an axis extending through the
center of measurement probe housing 102. In use of the AACMM 100,
the base 116 is typically affixed to a work surface.
[0027] Each bearing cartridge within each bearing cartridge
grouping 110, 112, 114 typically contains an encoder system (e.g.,
an optical angular encoder system). The encoder system (i.e.,
transducer) provides an indication of the position of the
respective arm segments 106, 108 and corresponding bearing
cartridge groupings 110, 112, 114 that all together provide an
indication of the position of the probe 118 with respect to the
base 116 (and, thus, the position of the object being measured by
the AACMM 100 in a certain frame of reference--for example a local
or global frame of reference). The arm segments 106, 108 may be
made from a suitably rigid material such as but not limited to a
carbon composite material for example. A portable AACMM 100 with
six or seven axes of articulated movement (i.e., degrees of
freedom) provides advantages in allowing the operator to position
the probe 118 in a desired location within a 360.degree. area about
the base 116 while providing an arm portion 104 that may be easily
handled by the operator. However, it should be appreciated that the
illustration of an arm portion 104 having two arm segments 106, 108
is for exemplary purposes, and the claimed invention should not be
so limited. An AACMM 100 may have any number of arm segments
coupled together by bearing cartridges (and, thus, more or less
than six or seven axes of articulated movement or degrees of
freedom).
[0028] The probe 118 is detachably mounted to the measurement probe
housing 102, which is connected to bearing cartridge grouping 112.
A handle 126 is removable with respect to the measurement probe
housing 102 by way of, for example, a quick-connect interface. As
will be discussed in more detail below, the handle 126 may be
replaced with another device configured to provide non-contact
distance measurement of an object, thereby providing advantages in
allowing the operator to make both contact and non-contact
measurements with the same AACMM 100. In exemplary embodiments, the
probe 118 is a contacting measurement device and is removable. The
probe 118 may have different tips 118 that physically contact the
object to be measured, including, but not limited to: ball,
touch-sensitive, curved and extension type probes. In other
embodiments, the measurement is performed, for example, by a
non-contacting device such as an interferometer or an absolute
distance measurement (ADM) device. In an embodiment, the handle 126
is replaced with the coded structured light scanner device using
the quick-connect interface. Other types of measurement devices may
replace the removable handle 126 to provide additional
functionality. Examples of such measurement devices include, but
are not limited to, one or more illumination lights, a temperature
sensor, a thermal scanner, a bar code scanner, a projector, a paint
sprayer, a camera, or the like, for example.
[0029] As shown in FIGS. 1A and 1B, the AACMM 100 includes the
removable handle 126 that provides advantages in allowing
accessories or functionality to be changed without removing the
measurement probe housing 102 from the bearing cartridge grouping
112. As discussed in more detail below with respect to FIG. 2, the
removable handle 126 may also include an electrical connector that
allows electrical power and data to be exchanged with the handle
126 and the corresponding electronics located in the probe end
401.
[0030] In various embodiments, each grouping of bearing cartridges
110, 112, 114 allow the arm portion 104 of the AACMM 100 to move
about multiple axes of rotation. As mentioned, each bearing
cartridge grouping 110, 112, 114 includes corresponding encoder
systems, such as optical angular encoders for example, that are
each arranged coaxially with the corresponding axis of rotation of,
e.g., the arm segments 106, 108. The optical encoder system detects
rotational (swivel) or transverse (hinge) movement of, e.g., each
one of the arm segments 106, 108 about the corresponding axis and
transmits a signal to an electronic data processing system within
the AACMM 100 as described in more detail herein below. Each
individual raw encoder count is sent separately to the electronic
data processing system as a signal where it is further processed
into measurement data. No position calculator separate from the
AACMM 100 itself (e.g., a serial box) is required, as disclosed in
commonly assigned U.S. Pat. No. 5,402,582 ('582).
[0031] The base 116 may include an attachment device or mounting
device 120. The mounting device 120 allows the AACMM 100 to be
removably mounted to a desired location, such as an inspection
table, a machining center, a wall or the floor for example. In one
embodiment, the base 116 includes a handle portion 122 that
provides a convenient location for the operator to hold the base
116 as the AACMM 100 is being moved. In one embodiment, the base
116 further includes a movable cover portion 124 that folds down to
reveal a user interface, such as a display screen.
[0032] In accordance with an embodiment, the base 116 of the
portable AACMM 100 contains or houses an electronic circuit having
an electronic data processing system that includes two primary
components: a base processing system that processes the data from
the various encoder systems within the AACMM 100 as well as data
representing other arm parameters to support three-dimensional
(3-D) positional calculations; and a user interface processing
system that includes an on-board operating system, a touch screen
display, and resident application software that allows for
relatively complete metrology functions to be implemented within
the AACMM 100 without the need for connection to an external
computer.
[0033] The electronic data processing system in the base 116 may
communicate with the encoder systems, sensors, and other peripheral
hardware located away from the base 116 (e.g., a noncontact
distance measurement device that can be mounted to the removable
handle 126 on the AACMM 100). The electronics that support these
peripheral hardware devices or features may be located in each of
the bearing cartridge groupings 110, 112, 114 located within the
portable AACMM 100.
[0034] FIG. 2 is a block diagram of electronics utilized in an
AACMM 100 in accordance with an embodiment. The embodiment shown in
FIG. 2A includes an electronic data processing system 210 including
a base processor board 204 for implementing the base processing
system, a user interface board 202, a base power board 206 for
providing power, a Bluetooth module 232, and a base tilt board 208.
The user interface board 202 includes a computer processor for
executing application software to perform user interface, display,
and other functions described herein.
[0035] As shown in FIG. 2A, the electronic data processing system
210 is in communication with the aforementioned plurality of
encoder systems via one or more arm buses 218. In the embodiment
depicted in FIG. 2B and FIG. 2C, each encoder system generates
encoder data and includes: an encoder arm bus interface 214, an
encoder digital signal processor (DSP) 216, an encoder read head
interface 234, and a temperature sensor 212. Other devices, such as
strain sensors, may be attached to the arm bus 218.
[0036] Also shown in FIG. 2D are probe end electronics 230 that are
in communication with the arm bus 218. The probe end electronics
230 include a probe end DSP 228, a temperature sensor 212, a
handle/device interface bus 240 that connects with the handle 126
or the noncontact distance measurement device 242 via the
quick-connect interface in an embodiment, and a probe interface
226. The quick-connect interface allows access by the handle 126 to
the data bus, control lines, and power bus used by the noncontact
distance measurement device 242 and other accessories. In an
embodiment, the probe end electronics 230 are located in the
measurement probe housing 102 on the AACMM 100. In an embodiment,
the handle 126 may be removed from the quick-connect interface and
measurement may be performed by the noncontact distance measurement
device 242 communicating with the probe end electronics 230 of the
AACMM 100 via the interface bus 240. In an embodiment, the
electronic data processing system 210 is located in the base 116 of
the AACMM 100, the probe end electronics 230 are located in the
measurement probe housing 102 of the AACMM 100, and the encoder
systems are located in the bearing cartridge groupings 110, 112,
114. The probe interface 226 may connect with the probe end DSP 228
by any suitable communications protocol, including
commercially-available products from Maxim Integrated Products,
Inc. that embody the 1-wire.RTM. communications protocol 236.
[0037] FIG. 3A is a block diagram describing detailed features of
the electronic data processing system 210 of the AACMM 100 in
accordance with an embodiment. In an embodiment, the electronic
data processing system 210 is located in the base 116 of the AACMM
100 and includes the base processor board 204, the user interface
board 202, a base power board 206, a Bluetooth module 232, and a
base tilt module 208.
[0038] In an embodiment shown in FIG. 3A, the base processor board
204 includes the various functional blocks illustrated therein. For
example, a base processor function 302 is utilized to support the
collection of measurement data from the AACMM 100 and receives raw
arm data (e.g., encoder system data) via the arm bus 218 and a bus
control module function 308. The memory function 304 stores
programs and static arm configuration data. The base processor
board 204 also includes an external hardware option port function
310 for communicating with any external hardware devices or
accessories such as a noncontact distance measurement device 242. A
real time clock (RTC) and log 306, a battery pack interface (IF)
316, and a diagnostic port 318 are also included in the
functionality in an embodiment of the base processor board 204
depicted in FIG. 3.
[0039] The base processor board 204 also manages all the wired and
wireless data communication with external (host computer) and
internal (display processor 202) devices. The base processor board
204 has the capability of communicating with an Ethernet network
via an Ethernet function 320 (e.g., using a clock synchronization
standard such as Institute of Electrical and Electronics Engineers
(IEEE) 1588), with a wireless local area network (WLAN) via a LAN
function 322, and with Bluetooth module 232 via a parallel to
serial communications (PSC) function 314. The base processor board
204 also includes a connection to a universal serial bus (USB)
device 312.
[0040] The base processor board 204 transmits and collects raw
measurement data (e.g., encoder system counts, temperature
readings) for processing into measurement data without the need for
any preprocessing, such as disclosed in the serial box of the
aforementioned '582 patent. The base processor 204 sends the
processed data to the display processor 328 on the user interface
board 202 via an RS485 interface (IF) 326. In an embodiment, the
base processor 204 also sends the raw measurement data to an
external computer.
[0041] Turning now to the user interface board 202 in FIG. 3B, the
angle and positional data received by the base processor is
utilized by applications executing on the display processor 328 to
provide an autonomous metrology system within the AACMM 100.
Applications may be executed on the display processor 328 to
support functions such as, but not limited to: measurement of
features, guidance and training graphics, remote diagnostics,
temperature corrections, control of various operational features,
connection to various networks, and display of measured objects.
Along with the display processor 328 and a liquid crystal display
(LCD) 338 (e.g., a touch screen LCD) user interface, the user
interface board 202 includes several interface options including a
secure digital (SD) card interface 330, a memory 332, a USB Host
interface 334, a diagnostic port 336, a camera port 340, an
audio/video interface 342, a dial-up/ cell modem 344 and a global
positioning system (GPS) port 346.
[0042] The electronic data processing system 210 shown in FIG. 3A
also includes a base power board 206 with an environmental recorder
362 for recording environmental data. The base power board 206 also
provides power to the electronic data processing system 210 using
an AC/DC converter 358 and a battery charger control 360. The base
power board 206 communicates with the base processor board 204
using inter-integrated circuit (I2C) serial single ended bus 354 as
well as via a DMA serial peripheral interface (DSPI) 357. The base
power board 206 is connected to a tilt sensor and radio frequency
identification (RFID) module 208 via an input/output (I/O)
expansion function 364 implemented in the base power board 206.
[0043] Though shown as separate components, in other embodiments
all or a subset of the components may be physically located in
different locations and/or functions combined in different manners
than that shown in FIG. 3. For example, in one embodiment, the base
processor board 204 and the user interface board 202 are combined
into one physical board.
[0044] Referring now to FIGS. 4-9, an exemplary embodiment of a
probe end 401 is illustrated having a measurement probe housing 102
with a quick-connect mechanical and electrical interface that
allows removable and interchangeable device 400 to couple with
AACMM 100. In the exemplary embodiment, the device 400 includes an
enclosure 402 that includes a handle portion 404 that is sized and
shaped to be held in an operator's hand, such as in a pistol grip
for example. The enclosure 402 is a thin wall structure having a
cavity 406 (FIG. 9). The cavity 406 is sized and configured to
receive a controller 408. The controller 408 may be a digital
circuit, having a microprocessor for example, or an analog circuit.
In one embodiment, the controller 408 is in asynchronous
bidirectional communication with the electronic data processing
system 210 (FIGS. 2 and 3). The communication connection between
the controller 408 and the electronic data processing system 210
may be wired (e.g. via controller 420) or may be a direct or
indirect wireless connection (e.g. Bluetooth or IEEE 802.11) or a
combination of wired and wireless connections. In the exemplary
embodiment, the enclosure 402 is formed in two halves 410, 412,
such as from an injection molded plastic material for example. The
halves 410, 412 may be secured together by fasteners, such as
screws 414 for example. In other embodiments, the enclosure halves
410, 412 may be secured together by adhesives or ultrasonic welding
for example.
[0045] The handle portion 404 also includes buttons or actuators
416, 418 that may be manually activated by the operator. The
actuators 416, 418 are coupled to the controller 408 that transmits
a signal to a controller 420 within the probe housing 102. In the
exemplary embodiments, the actuators 416, 418 perform the functions
of actuators 422, 424 located on the probe housing 102 opposite the
device 400. It should be appreciated that the device 400 may have
additional switches, buttons or other actuators that may also be
used to control the device 400, the AACMM 100 or vice versa. Also,
the device 400 may include indicators, such as light emitting
diodes (LEDs), sound generators, meters, displays or gauges for
example. In one embodiment, the device 400 may include a digital
voice recorder that allows for synchronization of verbal comments
with a measured point. In yet another embodiment, the device 400
includes a microphone that allows the operator to transmit voice
activated commands to the electronic data processing system
210.
[0046] In one embodiment, the handle portion 404 may be configured
to be used with either operator hand or for a particular hand (e.g.
left handed or right handed). The handle portion 404 may also be
configured to facilitate operators with disabilities (e.g.
operators with missing finders or operators with prosthetic arms).
Further, the handle portion 404 may be removed and the probe
housing 102 used by itself when clearance space is limited. As
discussed above, the probe end 401 may also comprise the shaft of
an axis of rotation for AACMM 100.
[0047] The probe end 401 includes a mechanical and electrical
interface 426 having a first connector 429 (FIG. 8) on the device
400 that cooperates with a second connector 428 on the probe
housing 102. The connectors 428, 429 may include electrical and
mechanical features that allow for coupling of the device 400 to
the probe housing 102. In one embodiment, the interface 426
includes a first surface 430 having a mechanical coupler 432 and an
electrical connector 434 thereon. The enclosure 402 also includes a
second surface 436 positioned adjacent to and offset from the first
surface 430. In the exemplary embodiment, the second surface 436 is
a planar surface offset a distance of approximately 0.5 inches from
the first surface 430. This offset provides a clearance for the
operator's fingers when tightening or loosening a fastener such as
collar 438. The interface 426 provides for a relatively quick and
secure electronic connection between the device 400 and the probe
housing 102 without the need to align connector pins, and without
the need for separate cables or connectors.
[0048] The electrical connector 434 extends from the first surface
430 and includes one or more connector pins 440 that are
electrically coupled in asynchronous bidirectional communication
with the electronic data processing system 210 (FIGS. 2 and 3),
such as via one or more arm buses 218 for example. The
bidirectional communication connection may be wired (e.g. via arm
bus 218), wireless (e.g. Bluetooth or IEEE 802.11), or a
combination of wired and wireless connections. In one embodiment,
the electrical connector 434 is electrically coupled to the
controller 420. The controller 420 may be in asynchronous
bidirectional communication with the electronic data processing
system 210 such as via one or more arm buses 218 for example. The
electrical connector 434 is positioned to provide a relatively
quick and secure electronic connection with electrical connector
442 on probe housing 102. The electrical connectors 434, 442
connect with each other when the device 400 is attached to the
probe housing 102. The electrical connectors 434, 442 may each
comprise a metal encased connector housing that provides shielding
from electromagnetic interference as well as protecting the
connector pins and assisting with pin alignment during the process
of attaching the device 400 to the probe housing 102.
[0049] The mechanical coupler 432 provides relatively rigid
mechanical coupling between the device 400 and the probe housing
102 to support relatively precise applications in which the
location of the device 400 on the end of the arm portion 104 of the
AACMM 100 preferably does not shift or move. Any such movement may
typically cause an undesirable degradation in the accuracy of the
measurement result. These desired results are achieved using
various structural features of the mechanical attachment
configuration portion of the quick connect mechanical and
electronic interface of an embodiment of the present invention.
[0050] In one embodiment, the mechanical coupler 432 includes a
first projection 444 positioned on one end 448 (the leading edge or
"front" of the device 400). The first projection 444 may include a
keyed, notched or ramped interface that forms a lip 446 that
extends from the first projection 444. The lip 446 is sized to be
received in a slot 450 defined by a projection 452 extending from
the probe housing 102 (FIG. 8). It should be appreciated that the
first projection 444 and the slot 450 along with the collar 438
form a coupler arrangement such that when the lip 446 is positioned
within the slot 450, the slot 450 may be used to restrict both the
longitudinal and lateral movement of the device 400 when attached
to the probe housing 102. As will be discussed in more detail
below, the rotation of the collar 438 may be used to secure the lip
446 within the slot 450.
[0051] Opposite the first projection 444, the mechanical coupler
432 may include a second projection 454. The second projection 454
may have a keyed, notched-lip or ramped interface surface 456 (FIG.
5). The second projection 454 is positioned to engage a fastener
associated with the probe housing 102, such as collar 438 for
example. As will be discussed in more detail below, the mechanical
coupler 432 includes a raised surface projecting from surface 430
that adjacent to or disposed about the electrical connector 434
which provides a pivot point for the interface 426 (FIGS. 7 and 8).
This serves as the third of three points of mechanical contact
between the device 400 and the probe housing 102 when the device
400 is attached thereto.
[0052] The probe housing 102 includes a collar 438 arranged
co-axially on one end. The collar 438 includes a threaded portion
that is movable between a first position (FIG. 5) and a second
position (FIG. 7). By rotating the collar 438, the collar 438 may
be used to secure or remove the device 400 without the need for
external tools. Rotation of the collar 438 moves the collar 438
along a relatively coarse, square-threaded cylinder 474. The use of
such relatively large size, square-thread and contoured surfaces
allows for significant clamping force with minimal rotational
torque. The coarse pitch of the threads of the cylinder 474 further
allows the collar 438 to be tightened or loosened with minimal
rotation.
[0053] To couple the device 400 to the probe housing 102, the lip
446 is inserted into the slot 450 and the device is pivoted to
rotate the second projection 454 toward surface 458 as indicated by
arrow 464 (FIG. 5). The collar 438 is rotated causing the collar
438 to move or translate in the direction indicated by arrow 462
into engagement with surface 456. The movement of the collar 438
against the angled surface 456 drives the mechanical coupler 432
against the raised surface 460. This assists in overcoming
potential issues with distortion of the interface or foreign
objects on the surface of the interface that could interfere with
the rigid seating of the device 400 to the probe housing 102. The
application of force by the collar 438 on the second projection 454
causes the mechanical coupler 432 to move forward pressing the lip
446 into a seat on the probe housing 102. As the collar 438
continues to be tightened, the second projection 454 is pressed
upward toward the probe housing 102 applying pressure on a pivot
point. This provides a see-saw type arrangement, applying pressure
to the second projection 454, the lip 446 and the center pivot
point to reduce or eliminate shifting or rocking of the device 400.
The pivot point presses directly against the bottom on the probe
housing 102 while the lip 446 is applies a downward force on the
end of probe housing 102. FIG. 5 includes arrows 462, 464 to show
the direction of movement of the device 400 and the collar 438.
FIG. 7 includes arrows 466, 468, 470 to show the direction of
applied pressure within the interface 426 when the collar 438 is
tightened. It should be appreciated that the offset distance of the
surface 436 of device 400 provides a gap 472 between the collar 438
and the surface 436 (FIG. 6). The gap 472 allows the operator to
obtain a firmer grip on the collar 438 while reducing the risk of
pinching fingers as the collar 438 is rotated. In one embodiment,
the probe housing 102 is of sufficient stiffness to reduce or
prevent the distortion when the collar 438 is tightened.
[0054] Embodiments of the interface 426 allow for the proper
alignment of the mechanical coupler 432 and electrical connector
434 and also protect the electronics interface from applied
stresses that may otherwise arise due to the clamping action of the
collar 438, the lip 446 and the surface 456. This provides
advantages in reducing or eliminating stress damage to circuit
board 476 mounted electrical connectors 434, 442 that may have
soldered terminals. Also, embodiments provide advantages over known
approaches in that no tools are required for a user to connect or
disconnect the device 400 from the probe housing 102. This allows
the operator to manually connect and disconnect the device 400 from
the probe housing 102 with relative ease.
[0055] Due to the relatively large number of shielded electrical
connections possible with the interface 426, a relatively large
number of functions may be shared between the AACMM 100 and the
device 400. For example, switches, buttons or other actuators
located on the AACMM 100 may be used to control the device 400 or
vice versa. Further, commands and data may be transmitted from
electronic data processing system 210 to the device 400. In one
embodiment, the device 400 is a video camera that transmits data of
a recorded image to be stored in memory on the base processor 204
or displayed on the display 328. In another embodiment the device
400 is an image projector that receives data from the electronic
data processing system 210. In addition, temperature sensors
located in either the AACMM 100 or the device 400 may be shared by
the other. It should be appreciated that embodiments of the present
invention provide advantages in providing a flexible interface that
allows a wide variety of accessory devices 400 to be quickly,
easily and reliably coupled to the AACMM 100. Further, the
capability of sharing functions between the AACMM 100 and the
device 400 may allow a reduction in size, power consumption and
complexity of the AACMM 100 by eliminating duplicity.
[0056] In one embodiment, the controller 408 may alter the
operation or functionality of the probe end 401 of the AACMM 100.
For example, the controller 408 may alter indicator lights on the
probe housing 102 to either emit a different color light, a
different intensity of light, or turn on/off at different times
when the device 400 is attached versus when the probe housing 102
is used by itself. In one embodiment, the device 400 includes a
range finding sensor (not shown) that measures the distance to an
object. In this embodiment, the controller 408 may change indicator
lights on the probe housing 102 in order to provide an indication
to the operator how far away the object is from the probe tip 118.
In another embodiment, the controller 408 may change the color of
the indicator lights based on the quality of the image acquired by
the coded structured light scanner device. This provides advantages
in simplifying the requirements of controller 420 and allows for
upgraded or increased functionality through the addition of
accessory devices.
[0057] Referring to FIGS. 10-14, a device 500 is shown that allows
for non-contact measurement of an object. In one embodiment, the
device 500 is removably coupled to the probe end 401 via the
coupler mechanism and interface 426. In another embodiment, the
device 500 is integrally connected to the probe end 401. As will be
discussed in more detail below, the device 500 may be an
interferometer (FIG. 11) an absolute distance measurement (ADM)
device (FIG. 12), a focusing meter (FIG. 13 and FIG. 14) or another
type of non-contact distance measurement device.
[0058] The device 500 further includes an enclosure 501 with a
handle portion 510. In one embodiment, the device 500 may further
include an interface 426 on one end that mechanically and
electrically couples the device 500 to the probe housing 102 as
described herein above. The interface 426 provides advantages in
allowing the device 500 to be coupled and removed from the AACMM
100 quickly and easily without requiring additional tools. In other
embodiments, the device 500 may be integrated into the probe
housing 102.
[0059] The device 500 includes an electromagnetic radiation
transmitter, such as a light source 502 that emits coherent or
incoherent light, such as a laser light or white light for example.
The light from light source 502 is directed out of the device 500
towards an object to be measured. The device 500 may include an
optical assembly 504 and an optical receiver 506. The optical
assembly 504 may include one or more lenses, beam splitters,
dichromatic mirrors, quarter wave plates, polarizing optics and the
like. The optical assembly 504 splits the light emitted by the
light source and directs a portion towards an object, such as a
retroreflector for example, and a portion towards the optical
receiver 506. The optical receiver 506 is configured receive
reflected light and the redirected light from the optical assembly
504 and convert the light into electrical signals. The light source
502 and optical receiver 506 are both coupled to a controller 508.
The controller 508 may include one or more microprocessors, digital
signal processors, memory and signal conditioning circuits.
[0060] Further, it should be appreciated that the device 500 is
substantially fixed relative to the probe tip 118 so that forces on
the handle portion 510 do not influence the alignment of the device
500 relative to the probe tip 118. In one embodiment, the device
500 may have an additional actuator (not shown) that allows the
operator to switch between acquiring data from the device 500 and
the probe tip 118.
[0061] The device 500 may further include actuators 512, 514 which
may be manually activated by the operator to initiate operation and
data capture by the device 500. In one embodiment, the optical
processing to determine the distance to the object is performed by
the controller 508 and the distance data is transmitted to the
electronic data processing system 210 via bus 240. In another
embodiment optical data is transmitted to the electronic data
processing system 210 and the distance to the object is determined
by the electronic data processing system 210. It should be
appreciated that since the device 500 is coupled to the AACMM 100,
the electronic processing system 210 may determine the position and
orientation of the device 500 (via signals from the encoders) which
when combined with the distance measurement allow the determination
of the X, Y, Z coordinates of the object relative to the AACMM.
[0062] In one embodiment, the device 500 shown in FIG. 11 is an
interferometer. An interferometer is a type of distance meter that
sends a beam of coherent light, such as laser light for example, to
a point on an object. In the exemplary embodiment, the object is an
external retroreflector 516 for example. The interferometer
combines the returned light with a reference beam of light to
measure a change in distance of an object. By arranging the
retroreflector 516 at an initial position where the distance D is
known, as the retroreflector 516 is moved to a new position the
distance D' may be determined. With an ordinary or incremental
interferometer, the distance is determined by counting
half-wavelengths since the interference pattern of the light
repeats for every half wavelength of movement of the object point
relative to the distance meter. The retroreflector 516 may be a
spherically mounted retroreflector that comprises a metal sphere
into which a cube corner retroreflector is embedded. The cube
corner retroreflector comprises three perpendicular mirrors that
come together at a common apex point. In an embodiment, the apex
point is placed at the center of the metal sphere. By holding the
sphere in contact with an object, the distance to object surface
points may be measured by the interferometer. The retroreflector
516 may also be any other type of device that sends the light back
parallel to the outgoing light.
[0063] In an embodiment, the device 500 is an incremental
interferometer. The incremental interferometer has a measured
distance D calculated using D=a+(n+p)*(lambda/2)*c/n, where "a" is
a constant, "n" is the integer number of counts that have
transpired in the movement of a target, "p" is the fractional part
of a cycle (a number 0 to 1 corresponding to a phase angle of 0 to
360 degrees), "lambda" is the wavelength of the light in vacuum,
"c" is the speed of light in vacuum, and "n" is the index of
refraction of the air at wavelength of the light 524 at the
temperature, barometric pressure, and humidity of the air through
which the light 524 passes. The index of refraction is defined as
the speed of light in vacuum divided by the speed of light in a
local medium (in this case air), and so it follows that the
calculated distance D depends on the speed of light in air "c/n".
In an embodiment, light 518 from a light source 502 passes through
a interferometer optic 504, travels to a remote retroreflector 516,
passes through the interferometer optic 504 in a return path, and
enters an optical receiver. The optical receiver is attached to a
phase interpolator. Together the optical receiver and phase
interpolator include optics and electronics to decode the phase of
the returning light and to keep track of the number of
half-wavelength counts. Electronics within the phase interpolator
or elsewhere within the articulated arm 100 or in an external
computer determine the incremental distance moved by the
retroreflector 516. The incremental distance travelled by the
retroreflector 516 of FIG. 11 is D'-D. A distance D' at any given
time may be determined by first finding the position of the
retroreflector at a reference position, which might for example be
a distance D from a reference point on the articulated arm CMM. For
example, if the retroreflector resides within a spherically mounted
retroreflector (SMR), a distance D' may be found by first locating
the retroreflector 516 at a reference location, which might be for
example a magnetic nest configured to hold the SMR. Thereafter, as
long as the beam is not broken between the source of light 502 and
the retroreflector 516, the total distance D' can be determined by
using a reference distance as the value "a" in the equation
discussed hereinabove. A reference distance might be determined,
for example, by measuring a reference sphere with the scanner held
at a variety of orientations. By self-consistently solving for the
coordinates of the reference sphere, the reference distance can be
determined.
[0064] FIG. 11 shows an emitted outgoing beam of light 524
travelling parallel to, but offset from, the returning beam of
light 524B. In some cases, it may be preferable to have the light
return on itself so that the light 524 and 524B are traveling along
the same path but in opposite directions. In this case, it may be
important to use an isolation method to keep reflected light from
entering and destabilizing the light source 520. One means for
isolating the laser from the returning light is to place a Faraday
isolator in the optical pathway between the light source 502 and
the returning light 524B.
[0065] In one embodiment of an incremental interferometer, the
interferometer is a homodyne type of the device such that the light
source 502 is a laser that operates on a single frequency. In other
embodiments, the device may be a heterodyne type of device and the
laser operates on at least two frequencies to produce two
overlapping beams that are polarized and orthogonal. The light
source 502 emits a light 518 that is directed into a beam splitting
device 520. Here, a first portion 522 of the light is reflected and
transmitted to the optical receiver 506. The first portion 522 is
reflected off of at least one mirror 523 to direct the first
portion to the optical receiver 506. In the exemplary embodiment,
the first portion 522 is reflected off a plurality of mirrors 523
and the beam splitter 520. This first portion 522 is a reference
beam of light that used for comparison with a returned or reflected
light.
[0066] A second portion 524 of the light is transmitted through the
beam splitting device 520 and is directed towards the
retroreflector 516. It should be appreciated that the optical
assembly 504 may further include other optical components, such as
but not limited to lenses, quarter wave plates, filters and the
like (not shown) for example. The second portion 524 of light
travels to the retroreflector 516, which reflects the second
portion 524 back towards the device 500 along a path 527 that is
parallel to the outgoing light. The reflected light is received
back through the optical assembly where it is transmitted through
the beam splitting device 520 to the optical receiver 506. In the
exemplary embodiment, as the returning light is transmitted through
the beam splitting device 520, it joins a common optical path with
the light of first portion 522 to the optical receiver 502. It
should be appreciated that the optical assembly 504 may further
include additional optical components (not shown), such as an optic
that produces a rotating plane of polarization for example, between
the beam splitting device 520 and the optical receiver 506. In
these embodiments, the optical receiver 506 may be composed of
multiple polarization sensitive receivers that allow for power
normalization functionality.
[0067] The optical receiver 506 receives both the first portion 522
and the second portion 524 light. Since the two light portions 522,
524 each have a different optical path length, the second portion
524 will have a phase shift when compared to the first portion 522
at the optical receiver 506. In an embodiment where the device 500
is a homodyne interferometer, the optical receiver 506 generates an
electrical signal based on the change in intensity of the two
portions of light 522, 524. In an embodiment where the device 500
is a heterodyne interferometer, the receiver 506 may allow for
phase or frequency measurement using a technique such as a Doppler
shifted signal for example. In some embodiments, the optical
receiver 506 may be a fiber optic pickup that transfers the
received light to a phase interpolator 508 or spectrum analyzer for
example. In still other embodiments, the optical receiver 506
generates an electrical signal and transmits the signal to a phase
interpolator 508.
[0068] In an incremental interferometer, it is necessary to keep
track of the change in the number of counts n (from the equation
described hereinabove). For the case of which the beam of light is
kept on a retroreflector 516, the optics and electronics within the
optical receiver 506 may be used to keep track of counts. In
another embodiment, another type of measurement is used, in which
the light from the distance meter is sent directly onto the object
to be measured. The object, which might be metallic, for example,
may reflect light diffusely so that only a relatively small
fraction of the light returns to an optical receiver. In this
embodiment, the light returns directly on itself so that the
returning light is substantially coincident with the outgoing
light. As a result, it may be necessary to provide a means to
reduce the amount of light feeding back into the light source 502,
such as with a Faraday isolator for example.
[0069] One of the difficulties in measuring the distance to a
diffuse target is that it is not possible to count fringes. In the
case of a retroreflector target 516, it is known that the phase of
the light changes continuously as the retroreflector is moved away
from the tracker. However, if a beam of light is moved over an
object, the phase of the returning light may change
discontinuously, for example, when the light passes by an edge. In
this instance, it may be desired to use a type of interferometer
known as an absolute interferometer. An absolute interferometer
simultaneously emits multiple wavelengths of light, the wavelengths
configured to create a "synthetic wavelength," which might be on
the order of a millimeter, for example. An absolute interferometer
has the same accuracy as an incremental interferometer except that
it is not necessary to count fringes for each half wavelength of
movement. Measurements can be made anywhere within a region
corresponding to one synthetic wavelength.
[0070] In an embodiment, the optical assembly 504 may include a
steering mirror (not shown), such as a micro-electromechanical
system (MEMS) mirror that allows light from an absolute
interferometer to be reflected from the scanner and received back
by the scanner to measure rapidly over an area.
[0071] In one embodiment the device may include an optional image
acquisition device, such as a camera 529, which is used in
combination with an absolute interferometer. The camera 529
includes a lens and a photosensitive array. The lens is configured
to image the illuminated object point on a photosensitive array.
The photosensitive array is configured to be responsive to the
wavelengths of light emitted by the absolute interferometer. By
noting the position of the imaged light on the photosensitive
array, it is possible to determine the ambiguity range of the
object point. For example, suppose that an absolute interferometer
has an ambiguity range of 1 mm. Then as long as the distance to the
target is known to within one millimeter, there is no problem in
using the interferometer to find the distance to the target.
However, suppose that the distance to the target is not known to
within the ambiguity range of one millimeter. In one embodiment, a
way to find the distance to the target to within the ambiguity
range is to place the camera 529 near the point of emission of the
beam of light. The camera forms an image of the scattered light on
the photosensitive array. The position of the imaged spot of light
depends on the distance to the optical target and thereby provides
a way of determining the distance to the target to within the
ambiguity range.
[0072] In an embodiment, the distance measurement device uses
coherent light (e.g. a laser) in the determination of the distance
to the object. In one embodiment, the device varies the wavelength
of a laser as a function of time, for example, linearly as a
function of time. Some of the outgoing laser beam is sent to an
optical detector and another part of the outgoing laser beam that
travels to the retroreflector is also sent to the detector. The
optical beams are mixed optically in the detector and an electrical
circuit evaluates the signal from the optical detector to determine
the distance from the distance meter to the retroreflector
target.
[0073] In one embodiment the device 500 is an absolute distance
meter (ADM) device. An ADM device typically uses an incoherent
light and determines a distance to an object based on the time
required to travel from the distance meter to the target and back.
Although ADM devices usually have lower accuracy than
interferometers, an ADM provides an advantage in directly measuring
distance to an object rather than measuring a change in distance to
the object. Thus, unlike an interferometer, an ADM does not require
a known initial position.
[0074] One type of ADM is a pulsed time-of-flight (TOF) ADM. With a
pulsed TOF ADM, a laser emits a pulse of light. Part of the light
is sent to an object, scatters off the object, and is picked up by
an optical detector that converts the optical signal into an
electrical signal. Another part of the light is sent directly to
the detector (or a separate detector), where it is converted into
an electrical signal. The time dt between the leading edge of the
two electrical pulse signals is used to determine the distance to
from the distance meter to the object point. The distance D is just
D=a+dt*c/(2n), where a is a constant, c is the speed of light in
vacuum, and n is the index of refraction of light in air.
[0075] Another type of ADM is a phase-based ADM. A phased-based ADM
is one in which a sinusoidal modulation is directly applied to a
laser to modulate the optical power of the emitted laser beam. The
modulation is applied as either a sinusoid or a rectangle. The
phase associated with the fundamental frequency of the detected
waveform is extracted. The fundamental frequency is the main or
lowest frequency of the waveform. Typically, the phase associated
with the fundamental frequency is obtained by sending the light to
an optical detector to obtain an electrical signal, condition the
light (which might include sending the light through amplifiers,
mixer, and filters), converting the electrical signals into
digitized samples using an analog-to-digital converter, and then
calculating the phase using a computational method.
[0076] The phase-based ADM has a measured distance D equal to
D=a+(n+p)*c/(2*f*n), where "a" is a constant, "n" and "p" are
integer and fractional parts of the "ambiguity range" of an object
point, and "f" is the frequency of modulation, "c" is the speed of
light in vacuum, and n is the index of refraction. The quantity
R=c/(2*f*n) is the ambiguity range. If, for example, the modulation
frequency is f=3 GHz, then from the formula the ambiguity range is
approximately 50 mm. The formula for "D" shows that calculated
distance depends on the speed of light in air, "c/n". As in the
case of the absolute interferometer, one of the parameters that it
is desirable to determine is the ambiguity range for the object
point under investigation. For an AACMM 100 used to measure the
coordinates of a diffuse surface, the beam of light from the device
500 may in the course of a few milliseconds be directed to objects
separated by several meters. If the ambiguity range was not
determined, such a large change would likely exceed the ambiguity
range of the device and hence would leave the ADM without knowledge
of the distance to the object point.
[0077] In one embodiment the emitted light is modulated at a
plurality of frequencies so that the ambiguity range may be
determined in real time. For example, in one embodiment four
different modulation frequencies may be simultaneously applied to
laser light. By known means of sampling and extraction procedures,
the absolute distance to the target can be determined by
calculating the phase for each of these four frequencies. In other
embodiments, fewer than four frequencies are used. Phase-based ADMs
may be used at either near or far ranges. Modulation and processing
methods are possible with other types of incoherent distance
meters. Such distance meters are well known in the art and are not
discussed further.
[0078] In one embodiment shown in FIG. 12, the device 500 is an ADM
device that includes a light source 528, an isolator 530, ADM
electronics 546, a fiber network 536, a fiber launch 538, and
optionally a beam splitter 540 and position detector 542. The light
source 528 may be laser such as a red or infrared laser diode for
example. Laser light may be sent through an isolator 530, which may
be a Faraday isolator or an attenuator, for example. The isolator
530 may be fiber coupled at its input and output ports. ADM
electronics 532 modulates the light source 528 by applying a radio
frequency (RF) electrical signal to an input of the laser. In an
embodiment, the RF signal is applied through the cable 532 which
sinusoidally modulates the optical power of the light emitted by
the laser at one or more modulation frequencies. The modulated
light passing through the isolator travels to the fiber network
536. Some of the light travels over optical fiber 548 to the
reference channel of the ADM electronics 546. Another portion of
the light travels out of the device 500, reflects off target 516,
and returns to the device 500. In one embodiment, the target 516 is
a non-cooperative target such as a diffusely reflecting material
such as aluminum or steel. In another embodiment, the target 516 is
a cooperative target, such as a retroreflector target, for example,
that returns most of the light back to the device 500. Light
entering the device 500 passes back through the fiber launch 538
and fiber network 536 and enters the measure channel of the ADM
electronics 546 through the fiber optic cable 550. The ADM
electronics 546 includes optical detectors that convert the
reference and measure optical signals received from the optical
fiber 548 and 550 into electrical reference and measure signals.
These signals are processed with electronics to determine a
distance to the target.
[0079] In one embodiment, the light from the device 500 is sent to
a retroreflector rather than a non-cooperative (diffusely
scattering) target. In this case, a position detector 542 may be
included to receive a small amount of light reflected off a
beamsplitter 540. The signal received by the position detector 542
may be used by a control system to cause the light beam from the
device 500 to track a moving retroreflector 516. If a scattering
target is used rather than a retroreflective target, the
beamsplitter 540 and the position detector 542 may be omitted.
[0080] In one embodiment, the ADM device 500 incorporates a
configuration such as that described in commonly owned U.S. Pat.
No. 7,701,559 which is incorporated herein by reference. It should
be appreciated that both the interferometer devices and the ADM
devices determine the distance to the object at least in part based
on the speed of light in air.
[0081] Another type of distance meter is one based on a focusing
method. Examples of focusing distance meters are a chromatic
focusing meter, a contrast focusing meter, and an array sensing
focusing meter. A device using a chromatic focusing method such as
the one shown in FIG. 13, incoherent white light is generated by
the light source 552. Due to a chromatic aberration of a lens 554
in the optical assembly the light is focused in a "focal line" on
the object 556 based on the wavelength of light. As a result,
different wavelengths components of the white light are focused at
different distances. Using a spectrometer 557, the distance to the
object 556 may be determined.
[0082] Another type of focusing distance meter shown in FIG. 14 is
a contrast focusing device. In this embodiment, the distance to the
object is determined by focusing to a maximum contrast or image
sharpness. The focusing is achieved by moving a camera 558 along an
axis in the direction of the object 560. When the position of
greatest contrast has been found, the object 560 lies on the
optical axis of the sensor 562 at a known distance. This known
distance is predetermined during a calibration process.
[0083] In one embodiment, the device 500 may be an array sensing
focusing meter. In this type of device, a source of light sends
light through a lens and a beam splitter. Part of the light strikes
the object, reflects off the beam splitter, and travels to a
photosensitive array. If the object under inspection is at the
focal position of the spot of light, the light on the
photosensitive array will be very small. Hence the AACMM 100 could
be used to capture the 3D coordinates whenever the spot on the
array was sufficiently small.
[0084] In still another embodiment, the device 500 may be a
conoscopic holography device. In this type of device, the surface
of the object is probed by a laser point. The laser light is
diffusely reflected by the surface to form a point light source.
The light cone emanating from this point is widened by an optical
system. A birefringent crystal is arranged between two circular
polarizers to split the light into an ordinary beam and an
extraordinary beam. After transmitting through the second
polarizing lens, the two beams superimpose to generate a
holographic fringe pattern that may be acquired by a photosensitive
sensor, such as a CCD camera. The distance to the object is
determined from the interference fringes by image processing.
[0085] It should be appreciated that while the focusing devices and
the conoscopic holography devices may depend on the index of
refraction of light in air, the determination of distance for these
devices is independent of the speed of light in air.
[0086] While the invention has been described with reference to
example embodiments, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended claims.
Moreover, the use of the terms first, second, etc. do not denote
any order or importance, but rather the terms first, second, etc.
are used to distinguish one element from another. Furthermore, the
use of the terms a, an, etc. do not denote a limitation of
quantity, but rather denote the presence of at least one of the
referenced item.
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