Linear Array Optical Edge Sensor

FIG. 1 is a simplified block diagram of the system of this invention;

FIG. 2 symbolically depicts a lateral sensing line over a workpiece discontinuity and an array's signal profile;

FIG. 3 is a more detailed version of the system of FIG. 1;

FIG. 4 depicts a sequentially synchronous clamp and sampling circuit in accordance with this invention; and

FIG. 5 is a pulse and waveform chart which is useful in describing FIG. 4 of this invention.

This invention may be explained in a suitable environment, as depicted in FIG. 1, wherein a linear array 100 is shown in a cutaway perspective view. As seen in FIG. 1, the linear sensor array 100 comes about by stacking pairs of sensor units side by side. A plurality of illuminator lenses, such as lens 101, are in one row 100A and an equal number of detector lenses, such as lens 102, are in another row 100B. An illuminator lens 101 and its adjacent detector lens 102, with the corresponding emitter-detectors 150, 155, and the electro-optical light pipes 151, 156, create an intersection 106 of two optical cones 104, 105. Each pair of an emitter and detector unit defines a "pixel" in the linear array 100.

The mechanical and optical arrangement of illuminator and detector lenses defines the density or closeness of the pixel footprints in the linear array. Good position definition of a surface discontinuity along the linear array of pixels requires that the footprints of pixels should at least be adjacent to each other.

FIG. 2 depicts, in symbolic form, the optical axes of several very closely located side-by-side emitter-detector pairs. Such pairs sequentially emit and detect light from the surface of workpiece 200. It is, of course, assumed that the optical array has been fixably positioned at a relatively close distance to the workpiece. Each sensor pair develops a signal which is shown simply as a dot. In the expected linear array signal profile 50 of FIG. 2, light reflected from the upper or closer surface of work piece 200 develops an upper signal level 60 as shown by dots 51 and 52. Similarly, when light is reflected from the lower surface, as shown by dots 55 and 56, a lower signal level 70 is detected. Between the discrete signal dots on the upper and lower signal levels 60 and 70 is a signal transition level trace. The transition coincides with the discontinuity in workpiece 200 and includes signal dots 53 and 54. A middle level 65, halfway between the upper and lower signal levels 60 and 70, may be determined by any well-known signal processing circuit. The intersection of middle level 65 and the transition trace defines the detected location of the discontinuity. Computerized signal processing techniques for using signals, as represented by signal dots 51 through 56, are well known and need not be described here. Suffice it to say that the midpoint of the transition trace defines the linear edge under the laterally-located pixel array. That signal, once emitted from a signal processing circuit, is employed as a reference signal to guide robotic operations, such as spot welding, at spaced intervals along a linear edge of a workpiece.

The overall system configuration of the linear array electro-optical proximity sensor system is shown in FIG. 1. A standard video data terminal 110 is used to instruct the computer 115 with the specifics of the work, initiate the task, and provide operator interaction via a known data entry terminal. Computer 115 issues instructions to a sampling controller and signal digitizing unit 125. Unit 125 samples each emitter-detector pair in sequence and receives the digitized response. Computer 115 uses the measured values to compute the position of a surface feature on a workpiece. The results of each scan during setup are displayed on the video graphics display 120. These results may also be sent to a printer 130 or saved on a disk 140. The important point to note, however, is that a suitable reference signal is emitted at terminal 113 from computer 115, which signal is readily available for use by a control computer 112. Such a computer controls a robotic arm in a well-known manner.

FIG. 3 is a more detailed block diagram of FIG. 1 which depicts the system operation of this invention. Computer 115 provides an address code on output lead 116 to an address decoder 117. A start signal from computer 115 is also applied to the clock source 114. Sampling sequencer 118 provides a plurality of control signals that define the sampling process. A source enable signal on control lead 126 turns on one of the addressed light emitting diodes, as determined by the decoded address output from address decoder 117.

Light emitted from the addressed diode, such as 150, for example, travels through a fiber optic cable 151 to a lens 101. Emitted and focussed light is directed at a specific angle to be reflected from the workpiece surface 200 and to the complimentary-positioned detector lens 102. For ease of understanding and simplicity, the lens block 190, FIG. 3, is shown as two parts above and below the work surface 200. It should be understood, however, that the preferred embodiment has been described and depicted earlier in cutaway perspective in FIG. 1. Computer 115 also supplies the same address signal to a signal selector multiplexer 138, which multiplexer responds to the address by selecting the appropriate sensor 155 of the addressed pair 150 and 155. From the lens block, the light goes through another fiber optic cable 156 to the addressed detector diode 155.

Once the multiplexer 138 has gated out a signal from detector 155, that signal must be sampled and held by the sequential and synchronous lamp and sampling circuit 241. Sampling circuit 24 is defined as synchronous because its operation is in synchronism with the multiplexing operation of signal selector multiplexer 138. It is defined as sequential because it sequentially stores a difference signal which is free from significant impairment by ambient light. It also employs clamping in order to develop a driving signal that is filtered free from ambient light and high frequency noise impairments. The driving signal drives, in turn, a differential amplifier and an analog to digital converter 180 that supplies, for example, a twelve-bit binary data output signal of lead 190 to computer 115.

FIG. 4 depicts the sample clamp and hold circuit 241 in more detail. The waveforms of FIG. 5 are useful in explaining the operation of the circuit of FIG. 4. The sequence of operations for one sensor pair 150 and 155 will be described with the understanding that the operation is repeated for each emitter-detector pair. Every sensor pair may be sampled in turn, and the operation then repeated.

Sampling circuit 241 comprises four switches 243, 244, 246 and 247, which may advantageously be field effect switches. A signal selector multiplexer 138, in response to an address on lead 116 from computer 115, selects one out of sixteen separate detector input signals for this preferred embodiment. Each sampling sequence involves the computer 115 issuing an instruction in the form of a start pulse 300, FIG. 5, to sample each sensor pair, as was described earlier in connection with FIGS. 1 and 3.

Assume the system has been initialized and is in operation when the snapshot timing of FIG. 5 is taken. Light will have been coming in from one of the addressed detectors, such as detector 155, prior to time t.sub.0. Thus an ambient light level has been detected and has been stored in capacitors 253 and 254.

At time t.sub.0, waveform 310 turns "on" an addressed light emitting detector 151. Note that amplifier 252 has an output resistance 242, and that resistance, together with one of the two capacitors 253 and 254, acts both as a signal coupler and then as a filter, depending upon the timing sequence for switches 243 and 244. For example, when LED 151 is first turned "on" and switch 243 is "off", and resistor 242 and capacitor 253 act as a signal coupling circuit, while resistor 242 and capacitor 254 act as a filtering circuit through closed switch 244.

During clock time t.sub.0 through t.sub.5, as shown by waveform 311, FIG. 5, switch 243 is "off." That "off" condition acts as a high impedance, and thus the signal change delivered via amplifier 252 is coupled through capacitor 253 and through the amplifier 259. The output of amplifier 259 settles to the maximum coupled voltage just prior to time t.sub.5. At time t.sub.5, switch 246 is turned "on" and it stays "on" through t.sub.5 and t.sub.6. While switch 246 is closed, capacitor 255 is charged through resistor 248, as driven by amplifier 256 and closed switch 246. Thus, a clamped and filtered signal is present at the upper input of differential amplifier 260.

At time t.sub.6, the circuit responds to a negative-going signal change which is caused when LED 151 is turned off and the circuit returns to the lower ambient light condition. At time t.sub.6, switch 243 turns "on" and switch 244 turns "off". Resistor 242 and capacitor 254 act as a coupling circuit into amplifier 257, while resistor 242 and capacitor 253 act as a filtering circuit. The negative change condition settles at the output of amplifier 257 and then at time t.sub.11, switch 247 is turned "on" and remains "on" to time t.sub.12. This circuit action charges capacitor 256 through resistor 258. The charge is supplied to the lower side of differential amplifier 250 and is algebraically added to the earlier voltage. Waveform 316 shows the progression and final output from amplifier 260.

Since ambient light is always being detected from each diode detector, it is the change in light from an LED and detector pair which supplies the usable signal of interest. Indeed, the background light sensed by the detector is a source of noise that must be eliminated. Sampling circuit 242, including capacitors 253, 254 and switches 243, 244, acts as earlier described, as an ambient light clamping and correction means and as a high frequency filter means.

All charges on capacitors 255 and 256 must be restored to ground level before another sequence is started. In order to restore those capacitors to a ground level, switches 246 and 247 are turned "on." Similarly, switches 243 and 244 are "on." With all four switches "on" between t.sub.15 and the new t.sub.0, both sides of capacitors 255 and 256 are grounded, and they discharge through resistors 248 and 258 back to a ground level. Accordingly, waveform 316 also drops back to ground before the next sampling sequence is started.

During time t.sub.16 through t.sub.0, at the next start pulse 320, computer 115 is available for operator interaction. Once the desired computer tasks are accomplished, computer 115 addresses the next pair of LED and detector diodes. Each digitized output is stored so that a record of detected light levels is available in memory. The detected signal permits linear edge detection, robotic welding or the like.

In summary, it should now be clear that noise due both to ambient light and high frequency electrical noise is eliminated to a significant degree by this invention. Thus, a higher signal-to-noise capability is provided by this invention.

The above description presents the best mode contemplated in carrying out our invention. Our invention is, however, susceptible to modifications and alternate constructions from the embodiments shown in the drawings and described above. Consequently, it is not the intention to limit the invention to the particular embodiments disclosed. On the contrary, the invention is intended and shall cover all modifications, sizes and alternate constructions falling within the spirit and scope of the invention, as expressed in the appended claims when read in light of the description and drawings.