Automated optical metrology computer aided inspection station and method of operation

Abstract

An automated 3D Optical Metrology Scanning and Computer Aided Inspection System for dimensional inspection of precision manufactured parts. The system example and implemented configuration is based within a relocatable cabinet providing ambient light and optional temperature control. The cabinet further includes a part placement area having an optical metrology scanner positioned over a multi-axis robotic arm positioned in the part placement area. The robotic arm is constructed and arranged to grip and manipulate parts within a field of view of the optical metrology scanner. The robotic arm provides adequate multi-axis control to rotate and tilt and translate tp manipulate the part to allow substantially every surface of the part to be scanned. Dimensional comparison and analysis software application provide geometric conformance/deviation plus extraction of the dimensions indicated in the part computer aided design (CAD) model.

Claims

1. An Inspection System comprising: a relocatable cabinet having a controlled environment for ambient lighting control and to prevent thermal expansion from heat, humidity and eliminate measurement error from varying environmental light sources; a computer positioned within said cabinet, said computer capable of data storage and parallel-processing with hyper-threading through multiple processors at a high bus speed; a display screen positioned within said cabinet and coupled to said computer through a graphical processing unit; a part presenter positioner mounted within said cabinet and electrically coupled to said computer, said part presenter positioner available for rotational, linear, and angular positioning in response to commands from said computer from an integrated library script, wherein said part presenter positioner includes a base for use in securing the part, said base movable through a field of view of said scanner by motors secured to said base allowing multi-axis manipulation under automated computer control; an optical digital 3D camera/scanner positioned above said part presenter positioner, said optical camera/scanner having a structured light source used to project a controlled fringe or raster patterns on the part, said fringe or raster patterns recorded as high resolution images with said digital 3D camera, said computer controlling said part presenter positioner for automated rotational and angular positioning to accurately complete a three dimensional digital scan file of the part being inspected; wherein said optical camera/scanner digitizes desired surfaces of a part positioned on said part presenter positioner to produce a 3D scan file wherein scans are merged together using positional and/or geometric features information to make a final consolidated 3D scan file, said digital 3D scan file is automatically compared to a nominal CAD model and/or blueprint of the part to permit geometric analysis, complete dimensional inspection and full dimensional inspection reporting operation on the part to be inspected, including porting the dimensional inspection results into Statistical Process Control databases.

2. The Inspection System according to claim 1 wherein optical camera/scanner is a 3D optical metrology scanner.

3. The Inspection System according to claim 1 wherein said geometric variation between the part and an original CAD image is shown in dynamic and static color plots illustrating geometric conformance and deviation of the part to the nominal CAD model with adjustable tolerance ranges.

4. The Inspection System according to claim 1 wherein said part presenter positioner is mounted into said cabinet as a module.

5. A method for full and complete dimensional inspection of precision manufactured parts comprising the steps of: constructing a relocatable cabinet having a controlled environment to prevent thermal expansion from external heat, humidity and eliminate measurement error from varying environmental light sources wherein having a part placement area having a optical metrology scanner positioned above a part presenter positioner capable of multi-axis presentation of a part, said cabinet including a controller having a fast bus speed computer with parallel-processing, hyper-threading, multiple processors, CPU and GPU and data storage, said controller operating said optical metrology scanner for digitization of the surface of the part for dimensional analysis, inspection and report operation; positioning a part in need of inspection in said part presenter positioner; positioning the part with a multi-axis presentation provided by manipulating the part within a field of view of said optical metrology scanner through multi-axis controlled motion; stabilize any vibration of the part from motion; scan and capture an individual 3D scan; reposition the part to present another part surface to the scanner and repeat the reposition until an adequate number of 3D scans are captured; merge all of the individual 3D scans trim away non-part surfaces from the 3D scans; convert combined “point clouds” into a polygonized-mesh Stereo Lithography Scan.STL file, among other file formats; pass the Scan.STL file to an Inspection automation routine for dimensional comparison of said 3D scan file where geometric conformance/deviation is determined and displayed; provide a dimensional inspection report for traceability, trackability, and trendability of the inspected parts, whereby said optical camera/scanner digitizes desired surfaces of a part positioned on said part presenter positioned to produce a 3D scan file wherein scans are merged together using positional information to make a final consolidated 3D scan file, said digital scan file is compared to an original CAD model of the part to permit geometric analysis and perform a fully automated analysis, inspection and reporting operation on the part to be inspected.

6. The method for dimensional inspection of precision manufactured parts according to claim 5 including the step of providing a calibration artifact holder for use on said part presenter positioner and an integrated system calibration process routine for regular, automated, programmed, and on-demand use.

7. The method for dimensional inspection of precision manufactured parts according to claim 5 including the step of providing a library script of previously-developed inspection process setup files or inspection routines for automation of the inspection process.

8. The method for dimensional inspection of precision manufactured parts according to claim 7 wherein said library script is identified by a part number and/or part family program.

9. The method for dimensional inspection of precision manufactured parts according to claim 5 wherein said part number program is selected from the group consisting of: a bar code or QR code scan of a part paper router; a RFID tag; or an Optical Character Verification of the part identification information, among other data acquisition methods.

10. The method for dimensional inspection of precision manufactured parts according to claim 9 wherein said library script can be developed on the system through trained process development, or offline on separate systems for transfer into the library script of process setup files.

11. The method for dimensional inspection of precision manufactured parts according to claim 5 including the step of providing customizable operator/user interface devices by use of a bar code scanner, name tag, or badge security.

12. The method for dimensional inspection of precision manufactured parts according to claim 5 wherein said display allows video conferencing and online collaboration, or even remote operational control, training, and troubleshooting.

13. The method for dimensional inspection of precision manufactured parts according to claim 5 wherein said parts presenter positioner is further defined as a computer controlled robotic arm for manipulation of the part through the 3D scanner's field of view.

14. The method for dimensional inspection of precision manufactured parts according to claim 5 wherein said the comparison of the 3D scan of the part to the original/nominal CAD model of the part and to the in part inspection requirements from blueprint or product manufacturing information embedded in the CAD model producing results varying from a comprehensive dimensional quality inspection to a simple pass/fail determination.

15. The method for dimensional inspection of precision manufactured parts according to claim 5 wherein said the comparison of 3D scan file to the nominal CAD model of the part, and the analysis and inspection of the part is automatically performed dimensional data ported directly into Statistical Process Control database systems.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a perspective view of the inspection station;

[0021] FIG. 2 is a perspective cross sectional view of an inspection station illustrating component reconfiguration;

[0022] FIG. 3 is a perspective view of the parts presenter positioner assembly;

[0023] FIG. 4 is a side view of the parts presenter positioner;

[0024] FIG. 5 is a front view of the parts presenter positioner; and

[0025] FIG. 6 is a flow schematic of the automated inspection station processes.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0026] The invention is an integrated, automated Optical Metrology 3D Scanner, Parts Presenter, and Computer Aided Inspection system that receives a part and rapidly performs all of the process steps required to create the desired inspection outcome determination with high levels of trendable, traceable, trackable results reporting for part disposition, process optimization, quality control, production stage monitoring, and Statistical Process Control, among other benefits, all with minimal non-technical operator effort beyond inserting the part(s) to be inspected and selecting by bar-code scanning a label to launch the automated routine, or simply hitting ‘Start’. This inspection part insertion can also readily be automated with robotics to completely eliminate human operators.

[0027] This invention consists of the following components (among other additions): [0028] 1. One or multiple 3D Scanner(s) with structured-light pattern source, projector and camera that produces 3D Scan files, e.g. in .STL file format [0029] a. 3D Scanner(s) can be any make or model or configuration that is selected to be applicable (e.g. adequate pixel resolution and appropriate data density) for the part size range, feature size, and dimensional tolerance of the parts to be inspected with their requirements [0030] 2. N-axis parts presenter(s) [0031] a. Non-technical operator places part to be inspected in parts presenter specific or generic gripper, or [0032] b. Robotic parts handler places part to be inspected in parts presenter gripper, and/or holds the part to be inspected directly in front of the scanner [0033] c. Parts presenter is also used for automated system calibration with the calibration plates being moved and placed in prescribed locations and angles to facilitate this calibration function [0034] 3. Optional M-axis scanner(s) positioner(s) for when scanner movement offers advantages in 3DS data capture [0035] 4. Optional Optical Character Verification Camera for automated Part Number and/or Serial Number identification and the ability to select and launch the automated part number routines in that manner. [0036] 5. Software applications, several, including [0037] a. 3D Scanning [0038] b. 2D Scanning for Optical Character Verification (OCV) [0039] c. Parts presenter and scanners positioner controls [0040] i. Capable of controlling up to 120 axes of motion (N+M≦120) if needed [0041] d. Analysis/inspection to compare the part scan to the CAD model and Blueprint inspection requirements, extracting dimensions, e.g. specified by the Blueprint or Parts Manufacturing Information (PMI) data, which can be any software that is adequate to perform the desired inspection functions [0042] i. Capable of batch processing multiple scan files of the same part number against the common inspection setup file [0043] e. Reporting to produce multiple and specific reporting forms, as needed to meet desired outputs or customer requirements [0044] f. Porting of dimensional inspection results data into Statistical Process Control (SPC) databases when available [0045] g. Optional Pass:Fail determination, including for part dispositioning based on dimensional inspection results and thresholds determined to be allowable for any number of dimensional features [0046] 6. ‘Orchestration software’ to command/control all of the above software applications and components automatically to produce 3D Scan files of parts, analyze those scan files against the parts reference files (CAD Model and Blueprint, among possible others), perform inspection process and produce any specified dimensional inspection reports, under part family or part number program(s) [0047] 7. Visual supercomputer to support running all of the above in parallel processing operations, including: [0048] a. Many CPU Cores [0049] b. Substantial amounts of Random Access Memory (RAM) to support multiple applications operating in parallel processing with hyper-threading and multitasking capabilities to share software application load across the RAM [0050] c. One or multiple Graphics Processing Units (GPUs) [0051] d. Substantial amounts of Read Only Memory (ROM) [0052] e. Substantial amounts of Storage Memory to facilitate 3D graphics files, many software applications, many part number programs, and the processing inspection files and generation of inspection reports for storage on the system or on the network (if available) [0053] f. Operator interface devices, including (but not limited to) [0054] i. Monitor(s) [0055] ii. Keyboard [0056] iii. Mouse [0057] iv. Bar-code reader and/or badge reader (RFID or other standard) and/or Optical Character Verification (OCV) to identify PN Program to activate for scanning and inspection routines, or any other data needed for input or control [0058] v. Optional Microphone for voice-recognition commands issuing to the system [0059] vi. Audio output capability and speakers to alert/indicate when processes are completed or needing input or attention [0060] g. Internet connectivity for remote control, part number programming, testing and diagnostics, file-transfer and online collaboration, among other networked uses [0061] 8. Un-interruptible Power Supply (UPS) to provide electric power conditioning and power stability [0062] 9. Optional Relocatable Cabinet (depending on configuration and size of parts to be scanned) to house all of the above components, with benefits of: [0063] a. Ambient lighting control [0064] b. Optional work envelope temperature control (air conditioned if needed) [0065] c. Rack for mounting visual supercomputer, UPS, and possible structured light source and/or projected image controller [0066] d. Modular construction for fitting through standard doorways, in assembly components if needed. [0067] e. Stabilizing, self-leveling, and shock-absorbing feet for vibration isolation, plus to provide clearance for pallet-jack or fork-lift use in system relocation [0068] f. Power cord and power strip for electrical supply to the above components. [0069] 10. The invention system Inspection Station is configurable with variable or interchangeable components to meet the inspection requirements or any other preference of the user, including 3D Scanner and Inspection Software application.

[0070] The Invention orchestrates, activates, and controls these multiple integrated and automated parallel processes: [0071] 1. Place part into parts presenter gripper by human or automated robot [0072] a. Select the Part Number Program desired [0073] b. Can be selected by drop-down menu, bar-code scan of part paper router, RFID tag, or Optical Character Verification of the part identification information, even directly from the part itself, among other Part Number Program selection options. [0074] 2. 3D scan the part to be inspected [0075] a. Move part and/or scanner to present part surface to scanner. [0076] b. Stop and stabilize any vibration from motion [0077] c. Capture individual 3D scan “A” [0078] d. Move part and/or scanner to present next part surface to scanner. [0079] e. Stop and stabilize any vibration from motion [0080] f. Capture individual 3D scan “B” [0081] g. Merge scan “B” with scan “A” [0082] h. Repeat 2d through 2g until adequate number of 3D scans of part to be inspected are captured and merged into single 3D scan file [0083] i. Trim away the gripper and any other non-part surfaces of the 3D scan file [0084] j. Convert combined “point clouds” into a polygonized-mesh Stereo Lithography Scan.STL file, or other file format that can be processed in the inspection software application functions [0085] 3. Pass the Scan.STL file off to the Inspection automation routine while next part is being automatically scanned. [0086] 4. “Ding” to notify the operator (if an operator exists) to remove the scanned part from the parts presenter gripper and input the next part to be scanned into the parts presenter gripper. Start Step 2. [0087] 5. 3D inspect the part 3D scan (while the next part is being scanned) [0088] a. Align the Scan.stl file to the part CAD model in prescribed manner from several available options [0089] b. Generate 3D comparison of part scan to nominal CAD model, showing geometric conformance and deviation by color-plot in any applicable range of color gradations to meet the objective and requirements [0090] c. Extract all or selected dimensions identified in the blueprint drawing inspection requirements for each part sample in the inspection project, serially or in batch processing [0091] d. Populate multiple dimensional inspection reports, as needed, possibly including, but not limited to: [0092] i. AS9102 Dimensional Inspection Report Form (.xls) [0093] 1. Or any other dimensional inspection report form desired [0094] ii. Probability Studies (.xls) [0095] iii. Trend Reports (.xls) [0096] iv. Specialty Analysis Reports (.xls) [0097] v. Dimensional Inspection Report (.pdf) showing images for each feature from the blueprint with Scan and CAD, tables of features, nominal, tolerances, and measurements with Pass/Fail disposition. [0098] vi. Simple pass/fail reports with green/red indicators [0099] vii. Any desired output in .xml file format for porting into Statistical Process Control or other enterprise/quality/production management systems or databases. [0100] e. Post the reports package to designated directory location on the server, if not left on the system

[0101] Part Number programs for the scanning and inspection functions can be readily developed either on the invention system or offline using the same software applications on a separate computer to keep the inspection system operational and productive.

[0102] The invention can also be used to automatically develop Additive Manufacturing (AM) print files for 3D printing replicas of the scanned part by scanning an existing part and sending the scan file to the 3D printer.

[0103] The invention can also be used to automatically develop Computer Aided Design (CAD) files of the scanned part for use in manufacturing or inspection, among other uses.

[0104] For faster average throughput rates, multiple parts can also be scanned in the same automated routine, and the system has the ability to track serial numbers to the location in the multi-part gripper so that the inspection report can be directly related to the individual sample.

[0105] Referring now to FIG. 1, set forth is a pictorial view of an example configuration of the inspection station 10 which is specifically designed to consume a small footprint having a base 12, a top 14, and two side walls 16, 18. The side walls 16 and 18 of the inspection station are constructed and arranged to provide rack style mounting of components allowing ease of assembly, repair and configuration. The operation of the inspection station is controlled by a specialized computer 26, the computer includes parallel-processing, hyper-threading with multiple processors and a very fast bus speed. The computer includes a large amount of RAM, advanced graphical processing units (GPU) and substantial storage drives preferably with network access. A conventional keyboard 20 and cursor controller 22 are coupled to the computer 26 with display images projected onto the display screen monitor 24. A 3D optical camera/scanner is positioned above a parts presenter positioner 40.

[0106] The optical scanner digitizes the desired surfaces of the part and performs simultaneously, sequentially or in parallel, the post-processing analysis and inspection operations, automatically on the same stand-alone system. The part to be inspected is securely positioned within the parts presenter positioner 40 with a gripper that is specific to the part, the parts presenter positioned is rotated in the field of view of the 3D camera/scanner. Pull-down menus displayed on the screen monitor 24 are used to track and initialize the part-specific inspection routine by allowing data entry or bar-code or QR code scan launch of the scan, alignment to CAD model, and inspection processes within an automated CAI routine. The inspection report output can be highly variable, ranging from simple pass/fail determination to full dimensional inspection including geometric dimensioning and tolerancing (GD&T), as described in the associated part engineering design or inspection drawing. The inspection station 10 is configurable with interchangeable components including sensors, field of view lenses, alternate parts grippers and parts presenters, software applications, controllers and computers. An Integral Optical Character Verification (OCV) camera can be used to identify a part number to be inspected and call up from a library the specific part number automated scan-and-inspect routine.

[0107] The optical metrology scanner employed is an optical three-dimensional geometric measuring system which is based on the principle of triangulation or any other 3D digitization methodology. To create the object surface digital model, a structured light source is used to project controlled fringe or raster patterns on the object. These fringe patterns and their motion across the part surface are recorded as high resolution images with digital cameras. The data collected by these cameras is used to create a highly accurate and precise image of the object's entire surface. While contact measurement systems and devices provide a small set of landmark measurements on the object, optical metrology three-dimensional scanning can completely capture the entire surface of any 3D object. The scanner is capable of picking up at least tens of thousands of data points per second, and the highly automated process ensures consistency and quality. This highly accurate complete three-dimensional digital model is then compared to the object's original CAD model, and any geometric variation between the two is vividly shown in “color plots” with adjustable tolerance ranges as well as complete tables of measurement and deviation numbers. The increased ease of interpretation and understanding from these color plot reports is one of the key advantages of this method of geometric measurement and quality analysis. This process enables quick and accurate product inspection, such as prior to production implementation, or after periods of extended use and/or product remanufacture and so on. A comparative analysis of the CAD model to the actual product permits identification of imperfections. In addition, because optical metrology three-dimensional scanning is a non-contact and nondestructive analysis that encompasses the entire object, it is possible to reverse engineer the object based on the data collected during the scanning process. This allows the remanufacture of parts for which there are no CAD data. Optical metrology scanning is an important tool in the design and development of products, the tooling and fixturing for manufacture and the inspection of the product at any point in its life cycle.

[0108] An example part 100 is shown on the parts presenter positioned 40 held by a gripper for processing. An operator may control the inspection station by use of the keyboard 20 and mouse, responding to queries provided on the display screen 24, or simply let it operate in full automation modes. The parts presenter positioner positions the part 100 in accordance with computer issued instructions wherein the optical scanner 70 initiates the scan collection for merging and ultimately for comparison to the predetermined part parameters. Shown in FIG. 2, set forth is an illustration of the inspection station 10 which is constructed and arranged to house components by use of removable racks. A keyboard tray and mouse can be positioned on an upper rack 25. The computer 26 can be rack mounted as depicted beneath the upper rack 25 and a sensor/robotic controller is rack mounted as depicted by numeral 27. In this illustration configuration, the optical scanner 70 is held above the parts presenter positioner within rack 71 to minimize floor-space requirements, which is important in high-value manufacturing facilities. The parts presenter positioner 40 is at least a two axis robotics assembly, and may be a three or four axis or many more if needed robotic assembly having a base positionable beneath the optical scanner 70. The parts presenter positioner 40 is shown secured to a rack 39 allowing for ease of configuration.

[0109] The parts presenter positioner rack allows for interchangeable components including sensors, parts grippers, and parts presenters allowing multiple standard and custom system configurations to accommodate a reasonably wide range of part sizes, complexities, quantities, dimensional tolerances, scan data point density, inspection process speeds and analysis output formats. A part placed within the parts presenter positioner is scanned for dimensional comparison and analysis using preprogrammed software applications where geometric conformance/deviation plus dimensional extraction of those dimensions indicated in the part computer aided design (CAD) model and Blueprint are compared in two or three dimensions to meet requirements.

[0110] Now referring to FIG. 3, the part presenter positioner 40 is shown in the rack 39, the rack having front 43 and rear 45 attachment walls. The parts presenter positioner includes a base 42 which operates as a parts gripper, the base. The gripper base 42 is capable of circular rotation by use of a first control motor, as will be illustrated in later drawings, forming a calibration artifact holder. The gripper base 42 can also be angled by use of a second control motor in response to commands issued through the computer. In addition, the gripper base 42 may be raised vertically along a track 47. FIGS. 4 and 5 further illustrate the parts presenter positioner wherein the gripper base 42 is shown secured to an L-shaped bracket 46 having a horizontal extension 48 and a vertical extension 50. A cross brace 49 is used to assure rigidity between the horizontal and vertical 50 extensions. The horizontal base 42 is rotatable coupled to the L-shaped bracket 46 by use of a first drive motor 44. The drive motor 44 causing rotation of the base in response to commands provided by the computer operation which can be an automatic rotation in response to preprogrammed commands. The second motor 52 is attached to an upper section 64 of a support base 56, the motor provides angular adjustment of the L-shaped bracket 46 which thereby adjusts the angle of the gripper base 42. The support base 56 includes a lower section 62 having coupling fasteners 60 for securing to the rack 49. To maintain rigidity between the upper section 64 and the lower section 62 the use of support brackets 66 permit the use of lightweight bracket material while maintaining a very accurate and repeatable configuration.

[0111] The previously mentioned optical metrology scanner 70 is used to scan any part placed on the gripper base 42 for digitizing, performing dimensional analysis, inspection and report generation from the part scan. The parts presenter positioner 40 manipulates a part with rotational and tilting ability to make most every surface of the part available for scanning. Various gripping material, not shown, allows for the presentation and manipulation within a field of view of an optical metrology scanner, wherein the parts presenter positioner 40 is essentially a robotic arm having the presenter positioner forming a 2, 3 or 4 axis rotation and tilt and/or linear translation computer-controlled/integrated parts presenter positioner maneuverable with minimal or no human intervention. Personnel access can be limited by password or RFID access and can be integrated to work with current corporate RFID personnel badges or identification tags. Any required safety lockouts are integrated to stop system operations if breached and interrupted.

[0112] The inspection station provides an integrated automated 3D Optical Scanning and Computer Aided Inspection System and method for dimensional inspection of precision manufactured parts wherein the system provides a multi-axis presentation of a part, or multiple parts, in the part placement area with multi-axis parts presentation to the scanner provided by gripping and manipulating the part within a field of view of the optical metrology scanner, all of which is integrated, automated and computer-controlled. The computer is specifically designed to provide a very fast bus speed with parallel-processing, hyper-threading, multiple processors, including graphics processing units (GPU) when applicable, adequate data storage, and connection for the enterprise network and/or Internet, if desired. Upon scanning, the computer creates a scan file for individual or batch-processing, providing an analysis and an inspection and reporting operation on the part(s) to be analyzed. A pass/fail determination or a partial dimensional inspection report can be generated for sample testing large quantities, or a complete dimensional inspection report is generated for the parts or products as desired and programmed.

[0113] Referring in general to FIG. 6, the preferred method of scanning is as follows:

[0114] 1. Mounting a scanner in a very stable and rigid orientation positioned above a part placement work envelope area;

[0115] 2. Gripping the part to be inspected, or multiple parts to be inspected in the same Optical Scanner session;

[0116] 3. Manipulating the part(s) in the gripper within the field of view below the Optical Scanner sensor on a multi-axis computer-controlled/integrated parts presenter positioner that makes most all of the part surface available for scanning with no or minimal human intervention;

[0117] 4. Controlling by a computer having parallel-processing, hyper-threading, multiple processors, fast bus speed, large amounts of RAM, high-performance GPU, and substantial storage capacity, and the processing power to perform the Optical Scanner and part presenter positioner processes management at the same time as performing dimensional analysis, inspection and report generation on the (previous) part scan while scanning the next part;

[0118] 5. Providing for scan file accumulation in a designated directory/folder for more efficient batch-processing in the inspection and analysis and reporting operation, either while Optical Scanner is being performed, or after a user-defined set of part scans have been created;

[0119] 6. Including a calibration artifact holder for use on the parts presenter positioner and an integrated system calibration process routine for regular, automated and on-demand use,

[0120] 7. Including a complete library of previously developed inspection process setup files or inspection routines, which can also be developed on the system by trained process developers;

[0121] 8. Providing a customizable operator/user interface devices of mouse and keyboard, or optionally touch screen with simplified operator interface, both requiring (if desired) security login which allows access only to the inspection routines that the particular operator is authorized to perform;

[0122] 9. Allowing for videoconferencing, online collaboration, remote access and operations with web cameras, telecom and Internet/Network-based interactive sessions for any support need;

[0123] 10. Placing all of components in a single strong industrial server-style cabinet, complete with an integrated UPS and optional air conditioner (if needed in the operating environment), with lockable doors allowing only authorized access to any particular part of the system, mounted on locking casters for system mobility around the facility with solid retractable support feet for cabinet stability and vibration dampening if needed, when situated for inspection operations, and the simplicity of a single power-plug for operations, plus Ethernet connection for data and report transfer and off-loading from the system, as well as remote part number program implementation and testing, and operations;

[0124] 11. Accounting for physical access for robotic/automated part placement into the part presenter positioner by another integrated system;

[0125] 12. Configurable with variable or interchangeable components including sensors, field of view lenses, parts grippers, parts presenters, software applications, controllers and computers to allow multiple standard and custom system configurations to accommodate a reasonably wide range of part sizes, complexities, quantities, dimensional tolerances, scan data point density, inspection process speeds and analysis formats. Files can range from simple scan files, to pass/fail reports (even with green/red light indicators) through complete dimensional inspection reporting and integrating/delivering inspection output information directly into enterprise statistical process control (SPC) and enterprise/quality/production management systems.

[0126] While not shown, a calibration plate and or artifact can be used on the parts presenter positioner wherein an integrated system calibration process routine can be performed. Further, a library of previously developed inspection process setup files or inspection routines can be maintained to provide system flexibility for inspecting any parts which have a resident or accessible program. Connections to the inspection station allow for remote training, remote control, troubleshooting, training, video conferencing, and other online collaboration.

[0127] The Graphical User Interface and other software integration is achieved by an integral script that can placed within the chosen configuration software application and/or external to, or between, the chosen configuration software applications to tie them together for completely automated operations. The integration routines and programming can be modified and customized to the various configurations of the Inspection Station to meet inspection needs and requirements.

[0128] An example of an integral script is as follows: AutoSmartInspect code snippets:

[0129] The script is repeatable throughout the scanning cycle providing automatic rotation and tilting of the part until completely scanned. The scanner is capable of picking up tens of thousands of data points (or more) per second, and the scripting provides a highly automated process that ensures consistency and quality. Upon completion, the three-dimensional digital model is then compared to the object's original CAD model and any geometric variation between the two is vividly shown in “color plots” with adjustable tolerance ranges as well as complete tables of measurements and deviations. The increased ease of interpretation and understanding from these color plot reports is one of the key advantages of this method of geometric measurement and quality analysis. This process enables quick and accurate product inspection, such as prior to production implementation, or after periods of extended use and/or product remanufacture and so on. A comparative analysis of the CAD model to the actual product permits identification of imperfections. In addition, because optical metrology three-dimensional scanning is a nondestructive analysis that encompasses the entire object, it is possible to reverse engineer the object based on the data collected during the scanning process. This allows the remanufacture of parts for which there is no CAD data.

[0130] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

[0131] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

[0132] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.