U.S. patent application number 15/671794 was filed with the patent office on 2017-12-14 for high-speed volume measurement method.
The applicant listed for this patent is Michael J. Brinkman, James L. Doyle, JR., Michael H. Lane. Invention is credited to Michael J. Brinkman, James L. Doyle, JR., Michael H. Lane.
Application Number | 20170356782 15/671794 |
Document ID | / |
Family ID | 51525915 |
Filed Date | 2017-12-14 |
United States Patent
Application |
20170356782 |
Kind Code |
A1 |
Lane; Michael H. ; et
al. |
December 14, 2017 |
HIGH-SPEED VOLUME MEASUREMENT METHOD
Abstract
Disclosed is a method of non-contact volume measurement of an
object, the method including the steps of emitting a plurality of
light beams from three light sources on three axes; acquiring data
on a plurality of light intensities received from the plurality of
light beams; identifying a change in intensity in at least one of
the plurality of received light beams; determining a presence of
the object when the change in light intensity exceeds a
predetermined magnitude in a predetermined number of received light
beams; determining an end of the presence of the object when the
change in light intensity falls below the predetermined magnitude
in the predetermined number of received light sources; and
calculating a velocity of the object.
Inventors: |
Lane; Michael H.; (Clifton
Park, NY) ; Doyle, JR.; James L.; (Renton, WA)
; Brinkman; Michael J.; (Bellevue, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lane; Michael H.
Doyle, JR.; James L.
Brinkman; Michael J. |
Clifton Park
Renton
Bellevue |
NY
WA
WA |
US
US
US |
|
|
Family ID: |
51525915 |
Appl. No.: |
15/671794 |
Filed: |
August 8, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14930859 |
Nov 3, 2015 |
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15671794 |
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14088567 |
Nov 25, 2013 |
9194691 |
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14930859 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01B 11/04 20130101;
G01F 17/00 20130101; G01B 11/245 20130101; G01B 11/24 20130101 |
International
Class: |
G01F 17/00 20060101
G01F017/00; G01B 11/24 20060101 G01B011/24; G01B 11/04 20060101
G01B011/04; G01B 11/245 20060101 G01B011/245 |
Goverment Interests
NOTICE OF GOVERNMENT RIGHTS
[0002] The United States Government has rights in this application
and any resultant patents claiming priority to this application
pursuant to contract DE-AC12-00SN39357 between the United States
Department of Energy and Bechtel Marine Propulsion Corporation
Knolls Atomic Power Laboratory.
Claims
1-34. (canceled)
35. A method of non-contact volume measurement of an object, the
method comprising the steps of: emitting a plurality of light beams
from three light sources on three axes; acquiring data on a
plurality of light intensities received from the plurality of light
beams; identifying a change in intensity in at least one of the
plurality of received light beams; determining a presence of the
object when the change in light intensity exceeds a predetermined
magnitude in a predetermined number of received light beams;
determining an end of the presence of the object when the change in
light intensity falls below the predetermined magnitude in the
predetermined number of received light sources; and calculating a
velocity of the object.
36. (canceled)
37. The method of claim 35 further comprising the step of providing
three-dimensional representations of the object.
38. The method of claim 37, wherein the step of providing
three-dimensional representations of the object comprises acquiring
cross-sectional data points on the detected object, and analyzing
the acquired cross-sectional data points.
39. The method of claim 35 further comprising the step of providing
volume measurements of the object.
40. The method of claim 35 further comprising the step of counting
the object.
41. The method of claim 35 further comprising the step of
performing a calibration procedure wherein the object has a known
size and shape.
42. The method of claim 35, wherein the step of acquiring data on a
plurality of light intensities received from the plurality of light
beams occurs simultaneously on each axis.
43. The method of claim 35, wherein the step of acquiring data on a
plurality of light intensities received from the plurality of light
beams occurs at different times for at least two axes.
44-58. (canceled)
Description
CLAIM TO PRIORITY
[0001] This application is a Divisional Application of U.S. Utility
application Ser. No. 14/930,859 filed on Nov. 3, 2015, which is a
Continuation Application of U.S. Utility application Ser. No.
14/088,567 filed on Nov. 25, 2013, now U.S. Pat. No. 9,194,691.
This application claims priority to both references, both of which
are hereby incorporated by reference in their entirety.
TECHNOLOGICAL FIELD
[0003] This present subject matter relates to systems and methods
of high-speed volume measurement.
BACKGROUND
[0004] Existing object sizing technologies include dynamic light
scattering, laser light diffraction, mechanical sieves, video
imaging, image analysis, and scanning light beam projection. The
technologies are limited to analyzing groups of objects, without
providing detailed information on dimensions or imperfections of
individual objects, and have other limitations as well. These
technologies are limited to creating two-dimensional object
signatures or object cross sections, with no ability to do
three-dimensional (3D) sizing analysis. Many times, the measured
object is stationary with the beam scanning the object multiple
times in order to obtain a size measurement. Some of these
measuring techniques, for example, use only a single light sheet or
beam. A single light sheet or beam apparatus allows for only a
single variable, however, which is insufficient for calculating
velocity. Such an apparatus can detect the presence of an object
when the light is shadowed, but has no way of calculating the
object size without knowing the object velocity. Thus a single
light sheet or beam is unable to determine object velocity,
requiring that object velocity be known in advance or input into
the measurement device. This is problematic, as object velocity
often varies or is unknown, such as with freely falling
objects.
[0005] For analyzing large numbers of objects or a steady feed,
video imaging and image analysis technologies are employed, but are
speed-limited because of limitations on processing power available
to perform the associated computer computations. Another object
measurement methodology uses scanning light beam projection.
Scanning light beam projection is used on single objects in a
process line and requires the object to be moving at a known or
predetermined velocity. Scanning light beam projection also
typically uses rotating mirrors, potentially leading to
inaccuracies.
[0006] There are several apparatuses embodying one or more of these
techniques. One such apparatus is disclosed in U.S. Pat. No.
4,659,937. This patent is described as a laser beam focused on a
single axis using a combination of cylindrical lenses and a
laser-detector pair used to detect defects and measure wire
diameter. Another reference (U.S. Pat. No. 6,927,409) is described
as disclosing the monitoring of the drawing of wire or metal bar
stock using rotary optical sensors to determine a product type and
to detect product defects. The rotary sensors measure the part in
two dimensions using polar coordinates. The sensor output is
compared to known product standards to determine the presence and
type of product and to detect any defects.
[0007] Yet another reference (U.S. Pat. No. 4,917,494) is described
as disclosing a time-of-flight optical system that uses two closely
spaced and substantially parallel light beams for measuring
particle sizes by recording the time-of-flight between the two
beams. Each light beam has a thin elongated cross-sectional shape
and the particles are passed through the apparatus in a vacuum
stream. Another reference (U.S. Pat. No. 5,164,995) is described as
disclosing an apparatus for measuring parts on a process line. The
parts typically move on a planar track between an optical emitter
and a detector pair, with compensations for voltage variations due
to any variation in vertical motion.
[0008] Other examples are disclosed in three references (U.S. Pat.
Nos. 5,383,021; 5,568,263; and 6,285,034), described as disclosing
a non-contact multi-sensor bolt-sizing apparatus in which bolts
move along a track, partially blocking laser beams to create
shadows on corresponding detectors. The disclosed apparatuses are
described as using sheets of laser light, both parallel and
perpendicular, to produce two-dimensional part images. These
apparatuses are unable to detect a part's velocity, however, unless
the part size is known in advance or obtained from evaluating part
profile information. Additionally, the parts must also be directed
in a desired orientation on a track in order to be measured. None
of these references disclose a way to measure parts in three
dimensions moving at an unknown velocity. They are limited to
two-dimensional object signatures or two-dimensional object cross
sections.
SUMMARY
[0009] Disclosed is a system and apparatus of non-contact volume
measurement. In certain exemplary embodiments, the sensor includes
first, second, and third laser sources configured to emit first,
second, and third laser beams; first, second, and third beam
splitters configured to split the first, second, and third laser
beams into first, second, and third beam pairs; first, second, and
third optical assemblies configured to expand the first, second,
and third beam pairs into first, second, and third pairs of
parallel beam sheets; fourth, fifth, and sixth optical assemblies
configured to focus the first, second, and third parallel beam
sheet pairs into fourth, fifth, and sixth beam pairs; and first,
second, and third detector pairs configured to receive the fourth,
fifth, and sixth beam pairs and convert a change in intensity of at
least one of the fourth, fifth, and sixth beam pairs resulting from
an object passing through at least one of the first, second, and
third parallel beam sheets into at least one electrical signal
proportional to a three-dimensional representation of the
object.
[0010] An exemplary method of non-contact volume measurement
includes the steps of emitting first, second, and third laser
beams; splitting the first, second, and third laser beams into
first, second, and third beam pairs; expanding the first, second,
and third beam pairs into first, second, and third pairs of
parallel beam sheets; focusing the first, second, and third
parallel beam sheets into fourth, fifth, and sixth beam pairs; and
receiving the fourth, fifth, and sixth beam pairs and converting a
change in intensity of at least one of the fourth, fifth, and sixth
beam pairs resulting from an object passing through at least one of
the first, second, and third parallel beam sheets into at least one
electrical signal proportional to a three-dimensional
representation of the object.
[0011] Certain exemplary methods further include the steps of
further comprising the step of forming a three-dimensional
representation of the object by converting a plurality of fourth,
fifth, and sixth laser beam electrical signal data proportional to
a cross section of the object into a spherical coordinate system
and interpolating spherical radii between the plurality of
converted cross-sectional electrical signal data. Still other
exemplary methods include the step of integrating at least three
cross sections together to form a three-dimensional representation
of the object. In certain methods, up to 10,000 three-dimensional
representations are formed per second. Still other exemplary
methods include the step of calculating a velocity of the object
based on a distance between two parallel beam sheets and a time
delay between when the object passes between a first of the two
parallel beam sheets and when the object passes through a second of
the two parallel beam sheets.
[0012] Yet another exemplary method includes the steps of acquiring
data on a plurality of light intensities received from three
mutually orthogonal light sources; identifying a change in
intensity in at least one of the plurality of received light
sources; determining a presence of an object when the change in
light intensity exceeds a predetermined magnitude in a
predetermined number of received light sources; acquiring
cross-sectional data points on the detected object; and determining
an end of a presence of an object when the change in light
intensity falls below the predetermined magnitude in the
predetermined number of received light sources. Certain exemplary
methods further include the steps of recording a time that the
presence of the object is detected; and recording a time that the
presence of the object is no longer detected.
[0013] Still another exemplary embodiment includes a computer
program product including a non-transitory computer readable medium
having stored thereon computer executable instructions that when
executed causes the computer to perform a method of non-contact
volume measurement, the method including the steps of receiving
data on light intensity of at least one of a first, second, and
third laser beams; detecting a change in light intensity in at
least one of the first, second, and third laser beams resulting
from an object passing through at least one of a first, second, and
third parallel beam sheet pairs; and converting the data on the
change in light intensity of at least one of the first, second, and
third laser beams into an electrical signal proportional to a
three-dimensional representation of the object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A description of the present subject matter including
various embodiments thereof is presented with reference to the
accompanying drawings, the description not meaning to be considered
limiting in any matter, wherein:
[0015] FIG. 1 illustrates an exemplary three-axis sensor;
[0016] FIG. 2 illustrates a single channel of an exemplary
sensor;
[0017] FIG. 3 illustrates an exemplary sensor optical layout;
[0018] FIG. 4A illustrates an exemplary detector signal
response;
[0019] FIG. 4B illustrates an exemplary calibrated profile;
[0020] FIG. 5 illustrates an exemplary beam cross section;
[0021] FIG. 6 illustrates an exemplary beam apodization;
[0022] FIG. 7 illustrates an exemplary rhomboid prism;
[0023] FIG. 8 illustrates an exemplary alternate rhomboid
prism;
[0024] FIG. 9 illustrates an exemplary sensor system block
diagram;
[0025] FIG. 10 illustrates an exemplary embodiment of real-time
data processing;
[0026] FIG. 11 illustrates an exemplary calibration procedure;
and
[0027] FIG. 12 illustrates a histogram of an exemplary object
categorization.
[0028] Similar reference numerals and designators in the various
figures refer to like elements.
DETAILED DESCRIPTION
[0029] FIG. 1 illustrates an exemplary three-axis non-contact
volume sensor 100. The sensor 100 is capable of measuring and/or
calculating object volumes at rates of up to approximately 10,000
objects per second. The exemplary embodiment of FIG. 1 is a
three-axis sensor, but additional axes can be used without
departing from the scope of the present subject matter.
[0030] FIG. 2 discloses an exemplary embodiment of a single channel
module of a non-contact volume sensor 100. In the exemplary
embodiment shown, measurements are taken on three axes having three
beam sheet pairs 19a/19b. In the exemplary embodiment of FIG. 2,
the three beam sheet pairs 19a/19b form three measurement planes.
Although the embodiment has three beam sheet pairs 19a/19b, only
one is shown for clarity. Each beam sheet pair 19a/19b has a source
1 and a corresponding pair of detectors 10 and 11, with outputs
from the detectors 10 and 11 combined to form a three-dimensional
profile. In the exemplary embodiment of FIG. 2, source 1 includes a
laser diode and focusing lens. Other lasers, such as HeNe lasers,
solid state lasers, or other beam sources known to those of skill
in the art may also be used without departing from the scope of the
present subject matter. The beam wavelength in this exemplary
example is in the red light range, 600-670 nm, but other
wavelengths may be used without departing from the scope of the
present subject matter. A violet or ultraviolet laser diode with a
wavelength below 410 nm, for example, may be used if a smaller beam
footprint (diameter) or higher measuring resolution is desired.
Emitters of still other wavelengths may be used without departing
from the scope of the present subject matter.
[0031] Measurements can be taken simultaneously on each axis, but
need not be, as the object may pass through the parallel beam sheet
pairs at different times depending on the location of the measured
object. In the exemplary embodiment of FIG. 2, each beam sheet pair
19a/19b is independent of other beam sheet pairs 19a/19b. The use
of three axes is exemplary only, as additional axes may be used
without departing from the scope of the present subject matter. In
the embodiment shown in FIG. 1, the sensor axes are arranged at
rotational angle of 120 degrees to each other, at an elevation
angle of about 35 degrees from the horizontal plane. These angular
offsets and elevations are exemplary only. Other values can be used
without departing from the scope of the present subject matter.
[0032] In this exemplary embodiment, an object 16 passes through
laser light sheets 19a/19b, with the object 16 creating shadows in
the light sheets 19a/19b. These shadows are focused onto detectors
10 and 11, which produce one or more electrical signals
proportional to a cross section of the object 16 as it passes
through the light sheets 19a/19b. In the exemplary embodiment of
FIG. 2, source 1 emits beam 2, which is split by a beam-generator
assembly 3 into a first and second parallel beams 4 and 5. The beam
splitter shown polarizes the first and second parallel beams 4 and
5 in the embodiment shown, but need not in other exemplary
embodiments. The beams 4 and 5 pass through beam expansion lenses
6, an apodizing filter/optical aperture 7, and beam-collimating
lenses 8. Lens generically refers to any optical assembly used by
those of skill in the art to focus or redirect light. Parallelism
is defined by the equation
.theta.=1/2*sin.sup.-1(2*.epsilon./W)
[0033] where .theta. is the angle that two beams or beam sheets
point toward each other, .epsilon. is the desired axial measurement
accuracy, and W is the object aperture of the beam 14. For an
.epsilon. of 0.0001 inches and an object aperture size W of 0.75
inches, .theta. is 0.008 degrees.
[0034] In exemplary embodiments using non-cylindrically symmetric
sources, the source may also contain a half wave plate 23, which
when turned rotates the polarization of incident laser beam 2. The
laser beam 2 passes through a beam-generator assembly 3, creating
parallel beam 4, which has a p-polarization, and parallel beam 5,
which has an s-polarization. The ratio in intensities between the
two beams is determined by the polarization of the input beam 2,
which is controlled by the half wave plate 23. Alternately, for
cylindrically symmetric beams such as HeNe lasers or circularized
laser diodes, the polarization of the incident laser beam may be
rotated by rotating the laser source, which eliminates the need for
a half wave plate.
[0035] The output of the beam-collimating lens assembly 8 is a pair
of beam sheet sheets 19a and 19b spanning the path of object 16.
Object 16 crosses light sheets 19a and 19b at different times,
creating temporally offset shadows (not shown) on collecting lenses
9, which focus the shadowed beams 19c and 19d onto detectors 10 and
11. The detectors 10 and 11 convert changes in beam intensity
resulting from these shadows into one or more electrical signals
proportional to the object cross-section and/or a three-dimensional
representation of the object. In certain exemplary embodiments, the
light can be focused through a polarizing beam splitter 17 prior to
reaching detectors 10 and 11. In certain exemplary embodiments,
mirrors 12 and 13 may be used to fold the optical path to reduce
the size of the measurement apparatus 100. Other optical components
known to those of skill in the art can be used in place of or in
addition to these components. For example, a phased emitter or a
wide stripe laser or laser array could be used to produce the light
sheets. Integrating spheres, apertured detectors, band-pass
filters, one or more receiver arrays, or other detection methods
known to those skilled in the art may be used without departing
from the scope of the present subject matter.
[0036] FIG. 3 illustrates an exemplary sensor optical layout. In
the exemplary layout of FIG. 3, a light sheet 19a is shown in an
orthogonal view of the exemplary embodiment of FIG. 1. In the
embodiment of FIG. 3, beams 4 and 5 (as shown in FIG. 2, for
example) exit the beam-generator assembly 3 as converging beams. A
beam-expanding lens assembly 6 causes the beams to diverge, and a
beam-collimating lens assembly 8 collimates the expanded beams to
form light sheets 19a and 19b (as shown in FIG. 2, for example). In
the exemplary embodiment shown, sheets 19a and 19b are configured
such that the width of the sheets exceeds the diameter of an object
16 traveling through the sheets plus the uncertainty of the
position of the object 16 as it travels through sheets 19a and 19b.
A collecting lens assembly 9 converges and focuses sheets 19a and
19b onto detectors 10 and 11.
[0037] FIG. 4A illustrates an exemplary detector signal response.
In the exemplary response of FIG. 4A, a time delay .tau. between
the object falling between the two parallel light sheets is equal
to
.tau.=(ts.sub.A+tos.sub.A)-(ts.sub.B+tos.sub.B)
[0038] where tsA and tsB are the start time of the of the data
sections for first and second data acquisition channels
respectively, and tosA and tosB are the object start times,
measured from the beginning of the respective data sections.
[0039] The velocity of object 16 is calculated from the distance
between light sheets 19a and 19b and a time delay between the
signals on detector channels 15 and 16. As the object 16 travels
through beam 19a and 19b, it causes the intensity of light received
at detectors 10, and 11 to decrease, corresponding to a
cross-sectional profile of object 16 as it passes through a beam
sheet. The same cross section profile appears for both detector
signal channels 15 and 16, but delayed in time for the second
detector signal 22 compared to the first detector signal 21. As the
physical spacing between beams 19a and 19b is known, the velocity
of the object 16 can be calculated based on the delay between the
signals on channels 15 and 16. The time delay .tau. is related to
the velocity V of the object traveling through the object aperture
14, according to the equation
V=d/[.tau.*sin(.theta.)]-.alpha..tau./2
[0040] where d is the separation between the two beams (as shown,
e.g., in FIG. 2), a is the acceleration of the object as it travels
through the beams, and .theta. is the angle of beams with respect
to the direction of motion of the object.
[0041] In certain exemplary embodiments, at least a portion of this
information is used to create a calibrated profile, as illustrated
in the exemplary calibrated object profile 40 of FIG. 4B. The
velocity of object 16, calculated by object travel time between
sheets 19a and 19b, is used to calibrate the time axis to the
x-axis, to create the particle cross section. Measurement
accuracies better than 0.1 percent of the sheet spacing are
achieved on the calibrated x-axis. Where objects are freely falling
vertically without air resistance, a is the acceleration due to
gravity. Since the distance is known, the data obtained is used to
convert the voltage signal to an output on the y-axis as a
representation of size of the object 16 passing through sheets 19a
and 19b as a function of time.
[0042] FIG. 5 is an illustration of an exemplary beam cross
section. In the beam shown in FIG. 5, each of the laser beams has a
long axis 57 and a short axis 58. The minimum short axis 18 beam
size across the aperture 14 is set by the Gaussian transmission
properties of the laser beam, according to the equation
.omega.= {square root over ((W*.lamda.[(.pi.*sin(.theta.)])}
[0043] where .omega. is the minimum spot size at the edges of the
aperture, W is the width of the aperture 14, .theta. is the angle
of light sheets with respect to the aperture, and .lamda. is the
wavelength of the laser beam. The long axis 57 beam size is set to
be larger than the object aperture 14, so that objects falling
through the beam do not extend beyond the beam edges. The diameter
of the object aperture 14 is larger than the object diameter plus
any uncertainty in the object position. In certain exemplary
embodiments, the long axis 57 of the beam has a flat top profile to
minimize variations in the beam intensity along that axis.
[0044] FIG. 6 illustrates an exemplary beam apodization. Beam
apodization is used in certain exemplary embodiments to create more
uniform emitted beam profiles by reducing variations in emitted
beam intensity. Variations in emitted beam intensity are
undesirable, as they can result in variations in detected beam
intensity that are unrelated to detection and/or measurement of
object 16. In the example shown in FIG. 6, the profile of expanded
laser beam 61 along the long axis 57 of FIG. 5 before the apodizing
filter 7 approximates a Gaussian function, with an intensity that
approaches zero at the edges of the beam. The Gaussian function is
defined by the equation 1=exp(-2*x.sup.2/.omega..sup.2), where x is
the distance from the center of the laser beam, and .omega. is the
characteristic expanded spot size on long axis 57.
[0045] As shown in FIG. 6, the Gaussian profile of beam 61 has
significant intensity variations. To flatten beam 61, apodizing
filter 7, which has variable transmission across long axis 57 of
the beam and a constant transmission across the short axis 58 of
the beam, is used. The apodizing filter 7 has an aperture (not
shown) which cuts the edges beam 61 to form apertured beam 62, and
an apodizing function characterized by an apodizing filter profile
63, to create apodized beam 64. The apodizing filter transmission
function has a minimum in the middle, increasing to a maximum at
the edge of the beam (as shown in elements 21 or 22 of FIG. 4A for
example). A typical transmission function is given by the
equations
T-exp(2*x.sup.2/.omega..sup.2-2*x.sub.a.sup.2/.omega..sup.2) if
-x.sub.a<x<x.sub.a, and
T=0 if x>x.sub.a or x<-x.sub.a
[0046] where x.sub.a is a constant equal to the half-width of the
apertured beam. After passing through apodizing filter 7, apodized
beam 64 has a profile approximating an optimal flat top profile on
the long axis 57.
[0047] FIG. 7 illustrates an exemplary view of a rhomboid prism.
The exemplary prism of FIG. 7 is used in an exemplary
beam-generator assembly 3. The exemplary beam-generator assembly
shown includes a rhomboid prism 24 and a secondary prism 25. The
rhomboid prism 24 includes optical surfaces 26-29. The degree of
parallelism between surfaces 27 and 28 is determined by the desired
accuracy .epsilon. and aperture size W as previously discussed. The
prism can be any optical material which transmits the beam. One
non-limiting example is BK7, but other optical materials may be
used without departing from the scope of the present subject
matter. The secondary prism 25 may be of a variety of shapes, such
as a triangle or rhomboid. To minimize the number of manufactured
components, the secondary prism 25 is depicted as a rhomboid with
identical dimensions to the rhomboid prism 24, but need not be. In
this exemplary embodiment, rhomboid prism 24 and secondary prism 25
are attached together with optical cement and polished to achieve a
uniform output surface for both the s-polarized beam 5 and
p-polarized beam 4. Other attachment mechanisms and methods known
to those of skill in the art may be used without departing from the
scope of the present subject matter.
[0048] Several surfaces on the prisms of this exemplary embodiment
optionally include optical coatings. The first reflecting surface
27 has a polarization-separating coating, which preferably has an
extinction ratio (Tp/Ts) of 1,000:1 on the transmitted beams 4 and
5. The second reflecting surface 28 also has a
polarization-separating coating to reflect the s-polarized beam 5
and further attenuate any residual p-polarization light in the beam
and achieves an extinction ration (Rs/Rp) better than 1,000:1.
These extinction ratios are exemplary only. Other extinction ratios
can be used without departing from the scope of the present subject
matter. The input edge 26 and output edge 29 of the rhomboid prism,
and the output edge 31 of the secondary prism are anti-reflection
coated with a reflection coefficient less than 0.5% to minimize
interference of secondary reflected beams with the primary system
beams (i.e. the beams that are to be measured). The coating
discussed here is exemplary only. Other coatings known to those of
skill in the art may be used without departing from the scope of
the present subject matter.
[0049] FIG. 8 illustrates an exemplary of an alternate prism
design. In this exemplary embodiment, the prism is used in
exemplary beam-generator assembly 3. In this embodiment, input beam
2 reflects off a reflective surface 32 before impinging on
polarizing surface 33 and splitting into polarized beams 4 and 5.
The polarizing surface 33 has a polarizing-separating coating which
reflects the s-polarized beam 5 and transmits the p-polarized beam
at an extinction ratio (Rs/Rp) exceeding 1,000:1. In this exemplary
embodiment, the second reflecting surface 28 needs only a
reflective coating, as Ts for the polarizing surface is low enough
that any light detected from the secondary beam will not interfere
with measurement of the primary beam. In this embodiment, input
surface 26 is on the secondary prism 25. The input surface 25 and
output surfaces 29, 31 have the same anti-reflection coatings
described in other embodiments above.
[0050] FIG. 9 illustrates an exemplary system block diagram of the
exemplary sensor 100 of FIG. 1. In the embodiment of FIG. 9, the
sensor 100 includes laser drive inputs 35 for the lasers, and
signal inputs 36 for the detector pairs 10 and 11. In the
embodiment shown, the laser drivers 37 are in sensor power module
38. The sensor power module 38 contains laser drivers 37, which
deliver power to the lasers 1, and power supply 40 for a detector
board (not shown). In certain embodiments, sensor power module 38
compensates for variations in beam intensity. At least one
amplified detector signal passes through sensor power module 38.
The detector pairs 10 and 11 produce electrical current signals,
which are in certain embodiments are optionally converted to
voltage signals by amplifiers 39 (shown in dashed lines on FIG. 9).
The bandwidth amplifier 39 must be large enough to resolve the
smallest measured object feature, and the gain must be sufficient
to deliver a measurable voltage signal.
[0051] In certain embodiments, module 38 corrects for variations in
laser power by sampling at least a portion of the transmitted beams
to detect any change in intensity of the transmitted beam 2. Any
changes in intensity are compensated for at the detectors 10, 11 so
that these changes are not incorrectly interpreted as an object
passing through beam sheets 19a/19b. In still other exemplary
embodiments, power module 38 includes a reference detector (not
shown) that detects beam amplitude as it is transmitted, so that
transmission variations are not counted as beam shadows.
[0052] The exemplary embodiment illustrated in FIG. 9 further
includes a data acquisition station 42, implemented here using a
computer 50 having a high-speed data acquisition board 43 with a
plurality of channels, in this example two per axis. Each channel
is measuring a beam pair (see, e.g., 19c/d of FIG. 2), with one
beam of the beam pair measured on one channel, and the other beam
of the beam pair measured on another channel. The computer 50
optionally includes at least one processor (not shown) as a
hardware device for executing software stored in a non-transitory
computer-readable medium. The processor can be any custom made or
commercially available processor, a central processing unit (CPU),
an auxiliary processor among several processors associated with
computer 50, a semiconductor based microprocessor (in the form of a
microchip or chip set, for example), a microcontoller, or generally
any device for executing software instructions. In certain
exemplary embodiments, the memory can have a distributed
architecture, where various components are situated remote from one
another. The processor is configured to execute software stored
within the memory, to communicate data to and from the memory, and
to generally control operations of the computer 50 pursuant to the
software. When the systems and methods described herein are
implemented in software, the methods are stored on any
non-transitory computer readable medium for use by or in connection
with any computer related system or method. In the context of this
document, a non-transitory computer readable medium is an
electronic, magnetic, optical, or other physical device or means
that can contain or store a computer program for use by or in
connection with a computer related system or method. The software
in the non-transitory computer-readable medium may include one or
more separate programs, and may be in the form of a source program,
executable program (object code), script, or any other entity
comprising a set of instructions to be performed.
[0053] The exemplary embodiment of FIG. 9 further includes a
software interface 44 configured to provide user control of the
data acquisition process, with a real-time display 45 showing
object cross-sections, and post processing analysis tools providing
3D representations 46 and volume measurements. If a reference
detector is used for each laser to make corrections for laser power
variations, additional amplifier channels and data acquisition
channels may be included. These additional components are not
shown.
[0054] FIG. 10 illustrates an exemplary embodiment of real-time
data processing 1000. In the embodiment shown, computer controls 47
are used to initiate data acquisition in step 1010. Computer
controls 47 include but are not limited to data rate, record
length, and/or trigger threshold. In this embodiment, data is fed
by data channels into an acquisition memory (not shown). The
software periodically transfers blocks of data from the acquisition
memory to computer (not shown) in step 1020. The computer 50
analyzes the data, looking for signal changes corresponding to a
detected object. In step 1030 a particle (object) is detected and
triggers image capture and is optionally counted in step 1035.
Typically, a detected object triggers on a channel when a signal
change exceeds a predetermined deviation from a threshold level.
This deviation is user-settable and must be large enough that noise
spikes or dust particles do not trigger detection and/or counting
of false objects, but small enough to allow detection by a sensor
of the smallest desired object size. When a detected object
triggers on a predetermined number of data channels, an object is
considered detected, and a data section is extracted from the data
block for each channel. Each data section has a fixed width t.sub.w
and a pre-trigger time t.sub.pt to insure that the full width of
the object is detected. Since the object is separately triggered on
each sensor, the time start is of the data section for the
triggered channel is separately recorded. In certain exemplary
embodiments, the beginning and end of a detected object are
detected by a separate algorithm. Each algorithm scans from the
beginning of the data section, looking for the time at which the
signal change exceeds a predetermined threshold. To minimize the
chance of a false detection, an averaging or other smoothing filter
may be applied to the data. To find the end of a detected object,
an algorithm performs an analysis from the end of the data section,
in the reverse direction. If there may be two or more detected
objects in a data section, the "end of object detection" algorithm
may be changed to start looking at a peak of the signal, moving in
a forward direction. In exemplary embodiments using filtered data,
when the filtered data falls below the threshold the end of the
object is detected.
[0055] In step 1040 velocity is calculated and if required a
scaling factor is applied. One example of how velocity is
calculated from the time delay is disclosed in the description of
the exemplary embodiment of FIG. 2. The horizontal axis of the
cross section, measured in the time domain, is converted to linear
units from the standard distance equation
X=t*V+1/2a*t.sup.2
[0056] If the velocity of the object is large enough (V>>a*t
for example), the equation simplifies to
X=t*V.
[0057] This calibration is applied in step 1050 and is used to help
calculate volume and dimensions and to prepare a two-dimensional
cross section in step 1055. These two-dimensional cross sections
are combined in step 1060 to calculate object volume and dimensions
to prepare a three-dimensional representation in step 1065. Data is
saved in step 1070.
[0058] FIG. 11 illustrates an exemplary calibration procedure 1100.
In the exemplary procedure shown in FIG. 11, data is collected and
transferred to a computer 1110. The time it takes for an object to
pass through the beams is calculated 1120. In certain exemplary
embodiments, the time axis is calibrated by passing precision
objects (not shown), through the sensor assembly 100. A precision
object is an object of known size and volume. These objects can be
as small as 0.004 inches in diameter, and can be accurately
measured to within 0.0001 inches. In certain exemplary embodiments
these precision objects are used to create an object profile based
on the light level and/or voltage measured at the detectors. These
profiles are compared to signals obtained from objects of unknown
size and shape and used to estimate the size and shape of an
unknown object. A delay .tau. between two signals is calculated
1130 and the temporal delay is converted into distance (inches in
this example) as a distance scale.
[0059] As an object 16 passes through the light sheets 19a/19b it
creates a shadow which is detected by detectors 19a/19b, which
result in a reduction in the output voltage of detectors 10 and 11,
which is calibrated in step 1150. The amplitude of the voltage
change V.sub.PEAK is related to the measured diameter of the object
.phi., and is used to calculate the calibration constant for the
voltage axis k according to the equation
k=.phi./V.sub.PEAK.
[0060] In certain embodiments, each detector response is calibrated
independently to allow for variations in beam intensity and
detector responsivity. This helps improve the accuracy of
converting optical or other beam power to electrical current. As
even different detectors of the same model can output a different
current for a detected optical power, it is important to compensate
for these differences by knowing how a detector responds to a
detected signal. Detectors can be calibrated to produce a
consistent output for a given signal from detector to detector by
knowing how a particular detector responds. (i.e., the relationship
between current and optical power can be different for different
detector types) and adjusting the detector as needed to ensure it
is calibrated. In certain exemplary embodiments, the constant is
used to calibrate the detector voltage output axis using the
equation
Z=A*V
[0061] where Z is the axis relating detector voltage to a linear
object dimension, and V is detector output voltage, and A is a
calibration determined based on how a detector behaves (i.e., its
power output for a given optical input power). These equations are
used to convert a cross section signal in the voltage-time domain
to a fully dimensioned cross section, as summarized in the example
shown in FIG. 11. This process is repeated for two additional axes
in step 1160. In the example shown the additional axes are
orthogonal to each other, but they need not be. Other angular
orientations can be used without departing from the scope of the
present subject matter.
[0062] FIG. 12 illustrates a histogram of an exemplary object
profile categorization. As shown in FIG. 12, measurements were
performed of objects of different sizes and shapes, with a
histogram of the measured profiles. In certain embodiments, a
three-dimensional profile representation is created from three
cross sections by combining the cross sections in a spherical
coordinate system and interpolating the spherical radii between
measured cross sections. Additional cross sections can be added to
increase the accuracy of a three-dimensional representation of the
object. The three-dimensional profile is an approximation of the
actual object based on a mapping of cross sections, and on points
between the cross sections an average value between two cross
sections is of the cross sections. In still other exemplary
embodiments, three-dimensional representations are created by
taking a radial difference between measured points and calculating
a geometric mean to estimate the radius in between points and
perform a smoothing function in the non-mapped areas to create the
three-dimensional representation. Inputs are taken from
measurements from three or more sets of parallel beams.
Interpolations can be done by any variety of smoothing algorithms
known to those of skill in the art.
[0063] It will be understood that many additional changes in the
details, materials, steps and arrangement of parts, which have been
herein described and illustrated to explain the nature of the
subject matter, may be made by those skilled in the art within the
principle and scope of the invention as expressed in the appended
claims.
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