SURFACE SENSING PROBE AND METHODS OF USE
20210356250 · 2021-11-18
Inventors
Cpc classification
A61B5/0077
HUMAN NECESSITIES
G01B11/14
PHYSICS
A61B2576/00
HUMAN NECESSITIES
G01B9/02083
PHYSICS
G01B9/02069
PHYSICS
G06T7/521
PHYSICS
G06F21/32
PHYSICS
G01B9/02094
PHYSICS
International classification
G01B11/14
PHYSICS
G06F21/32
PHYSICS
G06T7/521
PHYSICS
Abstract
Disclosed is a surface sensing apparatus, one embodiment having a source of coherent radiation capable of outputting wavelength emissions to create a first illumination state to illuminate a surface and create a first speckle pattern, an emission deviation facility capable of influencing the emission to illuminate the surface and create a second illumination state and a second speckle pattern, and a sensor capable of sensing a representation of the first and a second speckle intensity from the first and second speckle pattern. Also disclosed are methods of sensing properties of the surface, one embodiment comprising the steps of illuminating the surface having a first surface state with the source of coherent radiation emission, sensing a first speckle intensity from the surface, influencing a relationship of the surface to the emission to create a second surface state and sensing a second speckle intensity from the surface at the second surface state.
Claims
1. A method for determining a translation of a location on an object having a surface, the method comprising: illuminating a neighborhood of the location on the object with a source of coherent radiation emission having a beam centerline, a beam direction, and a beam waist thus creating an illumination state and a first speckle pattern; sensing the first speckle pattern; sensing a second speckle pattern produced by a translation of a position of the location on the object; and determining a translation of the location on the object from the first and second speckle patterns.
2. A method for determining a translation of at least two locations on an object having a surface, the method comprising: a source of coherent radiation comprising at least two coherent radiation emissions, each of the at least two coherent radiation emissions having a beam centerline, a beam direction, and a beam waist; each of the at least two coherent radiation emissions creating an illumination state and a speckle pattern; each of the at least two coherent radiation emissions illuminate a neighborhood of a unique location on the object; sensing a first speckle pattern for each of the at least two coherent radiation emissions; sensing a second speckle pattern for each of the at least two coherent radiation emissions; and determining a translation of each of the unique locations on the object from the first speckle pattern and the second speckle pattern for each of the at least two coherent radiation emissions.
3. The method of claim 2, wherein: the translation of each of the unique locations on the object comprises a translation of at least one position of at least one of the unique locations on the object; and the translation of at least one position of at least one of the unique locations on the object produces a second speckle pattern for each of the at least two coherent radiation emissions.
4. The method of claim 2, wherein the at least two coherent radiation emissions are produced by a beam replicating element configured to generate a pattern of replicated beams.
5. The method of claim 4, wherein the beam replicating element comprises a diffractive optical element beam splitter.
6. The method of claim 2, wherein the surface comprises a substantially flat surface and the beam direction of each of the at least two coherent radiation emissions are substantially perpendicular to the substantially flat surface.
7. A surface sensing apparatus to determine a translation of a location on an object having a surface, the surface sensing apparatus comprising: at least one laser source producing at least one beam of coherent radiation having a centerline, a beam direction, and a beam waist; the at least one beam of coherent radiation configured to illuminate a neighborhood of the location on the object; a sensor configured to detect a first speckle pattern corresponding to a first surface state and a second speckle pattern corresponding to a second surface state; and at least one processor in communication with at least one memory element including instructions that when executed cause the processer to calculate a translation of the location on the object from the first speckle pattern and the second speckle pattern.
8. The surface sensing apparatus of claim 7 wherein; the at least one beam of coherent radiation comprises at least two beams of coherent radiation wherein the at least two beams of coherent radiation are each configured to illuminate the neighborhood of a unique location on the object; the sensor being further configured to detect a first speckle pattern and a second speckle pattern for each unique location on the object; and the processor calculating a translation of each unique location on the object.
9. The surface sensing apparatus of claim 8, wherein the at least two beams of coherent radiation are produced by a beam replicating element configured to generate a pattern of replicated beams.
10. The surface sensing apparatus of claim 9, wherein the beam replicating element comprises a diffractive optical element beam splitter.
11. The surface sensing apparatus of claim 10, wherein the surface comprises a substantially flat surface and the beam direction of each of the at least two beams of coherent radiation are substantially perpendicular to the substantially flat surface.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025] In order that the manner in which the above-recited and other advantages and features of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
DETAILED DESCRIPTION OF THE INVENTION
[0037] A surface sensing system will now be described in detail with reference to the accompanying drawings. It will be appreciated that, while the following description focuses on an optical surface sensing system that probes surface position and orientation at a single surface element, the systems and methods disclosed herein have wide applicability and can be used for the determination of three-dimensional surface shape and object orientation of complex objects. For example, the surface sensing system described herein may be readily employed as a scanning system to rapidly determine dimensions, geometry, location, and orientation of a wide range of objects having surfaces that scatter radiation. The methods are not limited to the optical wavelength range and apply generally to electromagnetic and acoustic waves. The invention provides the capability of performing high-precision measurements at low cost without the shadowing and surface-access issues inherent in triangulation-based approaches. For example, the narrow illumination beam utilized in this invention allows for the measurement of high-aspect-ratio features of an object such as deep holes. In addition, the invention provides for enhanced range resolution and precision compared with time-of-flight approaches that measure the transit time of radiation scattered from the surface of an object. The invention applies to a wide range of measurement scales ranging from microscopic applications to laser-radar applications. Notwithstanding the specific example embodiments set forth below, all such variations and modifications that would be envisioned by one of ordinary skill in the art are intended to fall within the scope of this disclosure.
[0038] The phemonology utilized by this invention is described with reference to
s=i sin θ.sub.s cos ϕ.sub.s+jsin θ.sub.s sin cos ϕ.sub.s+k cos θ.sub.s. tm (1)
The height profile of surface element 110 is represented by
z.sub.s=z.sub.0+αx+βy, (2)
where
α=−tan θ.sub.s cos ϕ.sub.s
β=−tan θ.sub.s sin ϕ.sub.s (3)
[0039] Coherent illumination beam 120 with wavelength A and beam axis 123 propagates in the direction opposite to unit vector 122 as denoted in coordinate system 105 through spherical-polar angles (θ.sub.b,ϕ.sub.b) as
b=i sin θ.sub.b cos ϕ.sub.b+jsin θ.sub.b sin cos ϕ.sub.b+k cos θ.sub.b. (4)
[0040] In one embodiment, coherent illumination beam 120 is substantially a Gaussian laser beam. Other beam types, however, may also be utilized and will exhibit the same general behavior as described by the following theoretical analysis of Gaussian beams. Coherent illumination beam 120 has a beam waist located at waist position 124. The complex amplitude of a Gaussian beam propagating along the negative ζ axis of a Cartesian coordinate system (ξ,η,ζ) with waist position 124 located at the origin of coordinate system (ξ,η,ζ) is represented by
where the Rayleigh range z.sub.r is related to the 1/e.sup.2 intensity radius w.sub.0 at waist position 124 by
z.sub.r=πw.sub.0.sup.2/λ, (6)
and the beam intensity profile is expressed as
I=|.sub.0|.sup.2 exp[−2(ξ.sup.2+η.sup.2)/w.sup.2], (7)
where w is the 1/e.sup.2 intensity radius point ζ along the beam axis, which is given by
w=w.sub.0√{square root over (1ζ.sup.2/z.sub.r.sup.2)}. (8)
Within the paraxial approximation, the beam waist radius and the Rayleigh range are related to the f/# that represents the convergence rate of the beam by
[0041] The complex amplitude impinging on surface point 118 lying on surface element 110 at lateral coordinates (x, y) is obtained through the coordinate transformation,
that transforms the coordinate system in which the Gaussian beam is defined in Eq. (5) into coordinate system 105. Calculation of the quantity
ρ.sup.2=ξ.sup.2+η.sup.2 (12)
using Eq. (11) yields
ρ.sup.2=[(x−x.sub.b)sin ϕ.sub.b−(y−y.sub.b)cos ϕ.sub.b].sup.2+[(x−x.sub.b)cos θ.sub.b cos ϕ.sub.b+(y−y.sub.b)cos θ.sub.b sin ϕ.sub.b−(z.sub.0−z.sub.b+αx+βy)sin θ.sub.b].sup.2 (13)
Likewise
[0042]
ζ=(x−x.sub.b)sin θ.sub.b cos ϕ.sub.b+(y−y.sub.b)sin θ.sub.b sin ϕ.sub.b+(z.sub.0−z.sub.b+αx+βy)cos θ.sub.b (14)
Substitution of Eqs. (13) and (14) into Eq. (5) yields the complex amplitude of the Gaussian beam that impinges on the arbitrary surface point 118 lying on surface element 110:
[0043] The scattered complex amplitude v.sub.P.sup.+(x, y) emanating from point 118 is represented by multiplication of the incident complex amplitude at surface point 118 by the complex function g (x, y):
v.sub.P.sup.+(x, y)=v.sub.P(x, y)g(x, y). (16)
The complex function g (x, y) represents the phase change and reflection loss introduced by scattering from surface point 118. Fresnel propagation of v.sub.P.sup.+(x, y) to plane 134, located at z=L, yields
is the Fresnel propagation kernel.
[0044] In
[0045] In
The resulting intensity at detector 140 is
[0046] Note that for option (C) 153 that Q reduces to unity so that Eqs. (22)-(24) take on a particularly simple form with the phase term being reduced to a linear function of x′ and y′. Option (C) 153 shows one embodiment where detector 140 is at the Fourier transform plane of lens 130. Equations (19)-(20) and (22)-(24) with the additional equations they reference embody the phenomenology which is exploited in the invention.
[0047]
[0048] Generally, and not for limitation, parameters associated with the two system states in
TABLE-US-00001 TABLE 1 Parameter Name State 1 State 2 Illumination Wavelength λ1 λ2 Direction (θ.sub.b1, ϕ.sub.b1) (θ.sub.b2, ϕ.sub.b2) Waist offset (x.sub.b1, y.sub.bl,) (x.sub.b2, y.sub.b2,) Waist range offset z.sub.b1 z.sub.b2 Surface Height z.sub.01 z.sub.02 Lateral translation (0, 0) (Δx, Δy) Orientation (α.sub.1, β.sub.1) or (α.sub.2, (β.sub.2) or (θ.sub.s1, ϕ.sub.s1) (θ.sub.s2, ϕ.sub.s2) Orientation change (0, 0) (Δα, Δβ) Speckle intensity Location of tracked (x.sub.1, y.sub.1) (x.sub.2, y.sub.2) speckle Speckle shift (0, 0) (s.sub.x, s.sub.y)
[0049] Illumination state 1 is represented by coherent illumination beam 120 propagating along beam axis 123 in the direction opposite to unit vector 122. Coherent illumination beam 120 has beam waist position 124 and a first wavelength. Surface state 1 is represented by the location and orientation of surface element 110. Illumination state 2 is represented by coherent illumination beam 220 propagating along beam axis 223 in the direction opposite to unit vector 222. Coherent illumination beam 220 has beam waist position 224 and a second wavelength. Surface state 2 is represented by surface element 110 being translated and rotated into the position represented by repositioned surface element 210. Repositioned surface element 210 has surface normal unit vector 212 and intersects the z axis at intersection location 214 lying on plane 216. Point 250 represents a lateral translation of the center of surface element 110 to the center of repositioned surface element 210. Illumination state 1 and illumination state 2 may be the same or they may comprise parameters that are the same and parameters that are different between state 1 and state 2. For example, wavelength 1 may equal wavelength 2. Likewise, surface state 1 and surface state 2 may be the same or they may have parameters that are the same and parameters that are different between state 1 and state 2. For example, there may be no lateral translation or orientation change between surface state 1 and surface state 2. In addition, there may be no relative motion between surface state 1 and surface state 2 so that repositioned surface element 210 coincides exactly with surface element 110. System state 1 and system state 2 differ when at least one system parameter, represented by illumination parameters and surface parameters in Table 1, differ. Coherent illumination beam 120 and coherent illumination beam 220 may either be derived from the same coherent radiation source, or they may be derived from different coherent radiation sources. It is not necessary for coherent illumination beam 120 and coherent illumination beam 220 to be coherent with respect to each other. System state 1 produces speckle intensity pattern 1 at detector 140. System state 2 produces speckle intensity pattern 2 at detector 140. If coherent illumination beam 1 and coherent illumination beam 2 have a high degree of overlap at surface element 110 and repositioned surface element 210 so that substantially the same scattering cells are illuminated in system state 1 and system state 2, then speckle pattern 1 and speckle pattern 2 are highly correlated. This correlation may manifest itself as speckle pattern 1 and speckle pattern 2 being substantially identical except for a lateral shift in the speckle pattern at the location of detector 140. If a feature in speckle pattern 1 is located at position (x.sub.1, y.sub.1) at the location of detector 140 and this feature moves to position (x.sub.2, y.sub.2) in speckle pattern 2 at the location of detector 140, then the shift in the speckle pattern is denoted by
s.sub.x=x.sub.2−x.sub.1
s.sub.y=y.sub.2−y.sub.1 (25)
[0050]
x.sub.b+(z.sub.c−z.sub.b)tan θ.sub.b cos ϕ.sub.b=0
y.sub.b+(z.sub.c−z.sub.b)tan θ.sub.b sin ϕ.sub.b=0 (26)
For illumination directions with small angles, θ.sub.b«1,
x.sub.b+(z.sub.c−z.sub.b)θ.sub.b cos ϕ.sub.b=0
y.sub.b+(z.sub.c−z.sub.b)θ.sub.b sin ϕ.sub.b=0 (27)
[0051] Substantially satisfying Eq. (26) or Eq. (27) for both beam axis 123 and beam axis 223 produces a location in measurement space near z=z.sub.c on the z axis around which measurements are not significantly degraded by decorrelation between speckle pattern 1 and speckle pattern 2. The location of z.sub.c can be chosen to suit the application. A high degree of beam overlap can be achieved during a measurement by coordinating the waist offset and the illumination direction between system state 1 and system state 2 to substantially maintain the relations given by Eq (26) or Eq. (27).
[0052] The degree of overlap at the surface is a function of both beam displacement 378 and beam waist w at the surface element. For surface states with equal heights, z.sub.0=z.sub.0.sub.
Δr.sub.c=2θ.sub.b|z−z.sub.c|=2r.sub.b|1−z/z.sub.c|, (28)
where
r=√{square root over (x.sub.b.sup.2+y.sub.b.sup.2)}. (29)
The beam waist radius at z is
w=w.sub.0√{square root over (1+(z−z.sub.b).sup.2/x.sub.r.sup.2)}. (30)
An indication of the degree of overlap for surface elements with height z.sub.0 is given by
When γ=1, the beam axes intersect at the surface element and speckle correlation is high. When γ=0, the 1/e.sup.2 intensity points of the beams approximately touch, and there is very little beam overlap and a correspondingly low speckle correlation. For fixed z.sub.c there is a range of z values for which γ is high enough to provide good measurements. It is possible to achieve high γ values over long ranges. For example, if z.sub.b=0, r.sub.b=50 μm, z.sub.c=5 mm, and f/#=10, then γ≥0.9 over the range of 3.3 mm≤z≤10.0 mm. Furthermore, γ≥0.8 for z≥2.5 mm. If θ.sub.b=0 so that there is no beam tilt with respect to the z axis, i.e., z.sub.c=∞, then γ≥0.8 for |z|≥5.0 mm and γ≥0.9 for |z|≥10.0 mm. These results for y are insensitive to wavelength and hold from the ultraviolet to the far infrared.
[0053]
[0054] Measurement of speckle intensity can occur in any of numerous modes. For example, in one embodiment detector 140 is a two-dimensional detector array comprised of at least three detector elements or pixels. Detector element need not lie on a plane. In one embodiment of a two-dimensional detector array the pixels are closely packed and contiguous. In another embodiment detector 140 is a linear array comprised of at least two elements arranged in substantially a straight line. In one embodiment of a linear array, the array is aligned to substantially coincide with the direction of speckle shift. In another embodiment detector 140 is comprised of at least two separated detection elements. In one embodiment of at least two separated detection elements, said detection elements are positioned to be substantially aligned with the direction of speckle shift. In one embodiment of said substantially aligned detector elements, a time history of speckle intensity over a multiple set of system states is produced for each of said detector elements. In one embodiment of said time history, the set of system states is a continuous history produced by a smooth variation of at least one system parameter.
[0055] Step 450 of determining the speckle shift can be accomplished through any of many algorithms known by those skilled in the art. For example, speckle shift can be obtained through calculating a cross correlation of two sets of speckle intensity data. The location of the peak of the cross correlation provides the speckle shift. Enhanced precision is achieved through sub-pixel interpolation algorithms. Another example of a method for determining speckle shift is to utilize optical flow algorithms known to those skilled in the art. Yet another method for determining speckle shift is to compare the speckle intensity time histories produced by a set of system states and to determine the time delay associated with features in the speckle pattern to move between detector elements. In one embodiment the determination of speckle shift is performed by a processor in communication with a memory and containing machine instructions capable of determining a speckle shift.
[0056] Step 460 of calculating at least one system parameter is performed by relating speckle shift to changes in at least one system parameter through system calibration or through measurement equations derived from the analysis of speckle intensity as related to Eq. (19) or Eq. (22). System calibration may be achieved, for example, by compensating measurement equations for system errors or inaccuracies in the model from which the measurement equations are derived.
[0057] A generalized measurement equation is obtained by continuing the analysis that led to Eq. (19) and Eq. (22). Equations (19) and (22) indicate that the speckle pattern intensity can be formulated as the magnitude squared of a Fourier transform. The argument of the Fourier transform contains the spatial coordinates (x, y) of the speckle intensity at detector 140. The speckle shift resulting from transitioning from system state 1 to system state 2 is determined by keeping the arguments of the Fourier transform constant. The argument of the Fourier transform consists of all complex exponential phase terms in Eq. (19) or Eq. (22) that are linear in terms of the variables of integration x′ and y′. As long as the remainder of the integrand, excluding g (x′, y′), varies slowly with respect to x′ and y′ and y is high, the integral behaves approximately as the Fourier transform of g, weighted by the magnitude of the incident beam. Consequently, speckle pattern 1 and speckle pattern 2 are highly correlated and related by a simple shift. The behavior of the speckle shift is determined by writing the integrand as a magnitude multiplied by a complex exponential phase component. The phase is then expanded in a power series to obtain an approximation of the linear phase terms.
[0058] The phase function ϕ.sub.d of Eq. (24) is expanded in a power series as
[0059] The same results are applicable to the expansion of ϕ.sub.L of Eq. (20) if we set d=0. Equations (33) and (34) are therefore used in the general case. Option (C) 153 of
[0060] The complex amplitude incident on point 118 is expressed in terms of a magnitude and a phase component as:
Expansion(of Eq. (36) in a power series yields
ϕ.sub.P(x!,y′)=ϕ.sub.P0+ϕ.sub.Pxx′+ϕ.sub.Pyy′+ . . . , (37)
where the linear coefficients are
[0061] In one embodiment, the illumination parameters θ.sub.b, x.sub.b, and y.sub.b are small and Eq. (38) reduces to:
[0062] The measurement equation for relating speckle shift to system parameters for a specific operation mode is obtained by requiring that the total combined linear phase remain constant between system state 1 and system state 2:
ϕ.sub.Px.sub.
ϕ.sub.Py.sub.
[0063] In reference to
(x.sub.2, y.sub.2)=(−x.sub.1,−y.sub.1)=(s.sub.x/2,s.sub.y/2), (42)
and unless otherwise stated, that θ.sub.b=0 and z.sub.b=0. (It is not necessary to number the subscripts when the values of the parameter are the same for both state 1 and state 2.) These assumptions are for illustration only and do not reduce the generality of the results.
[0064] In
(x.sub.b.sub.
where the total combined waist offset shift between state 1 and state 2 is
b=x.sub.b.sub.
The resulting measurement equation is
which when solved for height yields
[0065] In the embodiment of detection option 153, κ=0, and Eq. (46) reduces to
When the height is large with respect to the Rayleigh range, z.sub.r«|z.sub.0|, and Eq. (46) reduces to
When both conditions κ=0 and z.sub.r«|z.sub.0| are satisfied, Eq. (46) takes the particularly simple form
so that there is an inverse proportionality between height and speckle shift. The relation between height and speckle shift is linear when the magnitude of the height is small with respect to the Rayleigh range |z.sub.0|«z.sub.r, and κ=0:
[0066] In
θ.sub.b=−x.sub.b/z.sub.c (52)
in order to satisfy Eq. (27) at position z.sub.c. The azimuth angles are ϕ.sub.b.sub.
The solution of Eq. (53) for height is:
In detection option 153 of
[0067] In
[0068] The azimuth angle of the surface orientation is given simply as
ϕ.sub.s=tan.sup.−1(s.sub.y/s.sub.x). (58)
[0069] Equation (57) is approximated well by the simplified expression
because the second and third terms in the denominator of the third factor are very small with respect to unity.
[0070] In
Since Eq. (60) has a high degree of dependence on the height, z.sub.0, an initial estimate of the height is needed to determine the proportionality constant. However, Eq. (58) applies here as well and the azimuth angle of the surface orientation is easily obtained without the necessity of estimating the height. One application of this option is to align a surface perpendicular to a beam. The knowledge of ϕ.sub.s provides feedback as to which direction to tilt the surface. The rate of speckle shift provides feedback as to how much additional tilt is required to achieve alignment.
[0071] In
(α.sub.1,β.sub.1)=(α,β)
(α.sub.2,β.sub.2)=(α+Δα,β+Δβ) (61)
The change in orientation is related to the speckle shift through
These expressions are approximated well by
[0072] In
And both the magnitude and direction of the lateral translation can be determined. The direction of motion is obtained from
ϕ.sub.m=tan.sup.−1(Δy/Δx)=tan.sup.−1(s.sub.y/s.sub.x) (65)
Determination of the magnitude of the lateral translation requires knowledge of the height, which may be known, estimated, or obtained through an auxiliary measurement.
[0073]
[0074]
[0075] It may be desirable to illuminate the object with an illumination spot array that simultaneously illuminates the neighborhoods of multiple locations and to determine the shift between first and second speckle patterns corresponding to each location. One embodiment for producing an illumination spot array is to use a beam replicating element that replicates the beam of coherent radiation at an array of locations. The beam replicating element may be a diffractive optical element beam splitter that replicates the incident beam into multiple directions. If the incident beam is a converging beam, then the multiple directions can form multiple spots.
[0076]
[0077]
[0078]
[0079]
[0080] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0081] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Although this invention has been described in the above forms with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.