Line-Up Vision System

The present application pertains to a system for aligning a workpiece in a flexible machining system, and more particularly to a vision system for aligning a workpiece in a machine without the use of a touch probe.

Robots are used for an increasing number of tasks, including the loading of workpieces in numerically controlled turning centers and other machining systems. One of the problems associated with robot loading of workpieces or parts is the proper alignment of the part in the machining system. Touch probes have been used to provide informational feedback which tells if the workpiece has been correctly placed into a set of jaws. However, in many machine turrets equipped with conventional tool holders a probe cannot touch both sides of a part, nor can they orient the part to the machine while sequentially probing. The part can be centered in the plane where it is being probed and be off center in other parallel planes.

The present invention comprises a line-up system for use with automated machining apparatus to test for part alignment in the apparatus using noncontacting sensing of the part. A light source is mounted for illuminating a portion of the part to be aligned and for keeping another portion of the part relatively dark. A camera is mounted for viewing the part to be aligned with the camera viewing an edge between the illuminated area and the dark area and with the camera providing a signal which indicates the position of the edge. The machining apparatus is actuated to slowly rotate the part so the camera can observe the location of the edge as the part rotates and means are provided for comparing the position of the edge relative to a predetermined position as the part is rotated.

FIG. 1 is a side elevation of a line-up vision system of the present invention for testing the alignment of a part in a machining apparatus.

FIG. 2 is a plan view of the line-up vision system of FIG. 1.

FIG. 3 is a block diagram of a control system for checking alignment of parts being loaded into a flexible machining system.

FIGS. 4A-10 are flow charts illustrating operation of the line-up vision system of the present invention.

A portion of a flexible machining apparatus 10 in which a line-up vision system 11 of the present invention can be used is disclosed in FIGS. 1 and 2. The apparatus includes a lathe 12 having a rotatable chuck 13 for holding a part or workpiece 17 extending vertically from the chuck 13. A camera 18 aimed toward part 17 is movably mounted on a robot 19. The camera can be moved back and forth relative to part 17 by a carriage 23 of the robot; can be moved up and down on a vertical post 24 and post 24 can be rotated as shown by a pair of arrows 25a, 25b to orient the camera relative to the part 17. A lamp 29 illuminates a portion 17a nearest the lamp 29 and leaves a relatively dark portion 17b on the side of the part away from lamp 29. A backdrop 30 of light colored material such as acetal, enables the camera to observe an edge E along the dark portion 17b of the part 17. When part 17 is rotated slowly by lathe 13 camera 18 observes any change in the location of edge E relative to a center line of vision 31.

When a symmetrical part 17, such as a cylinder, is mounted properly in chuck 13 the sharp edge E remains aligned with line 31 (FIG. 2) as part 17 is rotated. When the symmetrical part 17 is not centered in chuck 13 the edge E moves relative to line 31 causing the camera to provide a signal which indicates that part 17 is not properly centered in chuck 13. For example, improperly positioning of the part by robot 19 or the presence of metal chips between chuck 13 and part 17 can cause incorrect centering of the part. The machining apparatus can be programmed to reposition the part 17 and/or provide a warning signal to allow a human operator to correct a problem which causes incorrect centering of part 17.

The line-up vision system 11 (FIG. 3) includes a camera 18 such as the Honeywell HDS-232 made by Honeywell Visitronic, Englewood, Colo. The HDS-232 includes a plurality of pixels or photo-sensitive cells (not shown) arranged in a matrix inside camera 18. The individual pixels provide output signals determined by the location of the dark edge E of part 17 relative to line 31 through the center of camera 18. Camera 18 (FIG. 3) includes a microprocessor 35 and a read-only-memory (ROM) 36 having a program which uses pixel output signals to detect the location of edge E of part 17. Camera 18 develops a signal in ASCII code which gives location of edge E as observed by camera 18.

The signal from camera 18 is transferred by an interface 37, such as an RS-232 link to a basic module 41 having a program portion 42. The program portion 42 executes a continuous program that waits for a data transfer signal from a programmable logic controller (PLC) 43. The program then transfers data from camera 18 and processes the camera data. Interface signals are transferred between PLC 43 and basic module 41, and between PLC 43 and a robot control 47 and machine lathe 12. PLC 42 includes a program portion 50 which provides signals to module 41, control 47 and lathe 12. A basic module 41 which can be used in the present invention is the 1771-DB basic module made by Allen-Bradley, Systems Division, Highland Heights, Ohio. A programmable logic controller 42 which can be used is the Mini PLC-2/15 also made by Allen-Bradley. The PLC program receives signals from robot control 47 and lathe 12 through PLC 42 and communicates with the module 41 through block transfer of data. Robot control 47 operates the robot 19 and lathe 12 or other type of machine. Robot 19 may have equipment (not shown) for transferring parts 17 from a conveyor 48 (FIG. 1) to chuck 13 of lathe 12. A computer program written in "Basic" language for operating camera 18 and communicating with PLC 43 is as follows: ##SPC1##

Details of the operation of the camera and associated equipment is also disclosed in the flow charts of FIGS. 4A-10. FIGS. 4A, 4B comprise a flow chart which discloses the operation of the camera 18 and the associated apparatus of FIG. 3. The drawings of FIGS. 4A, 4B should be placed side-by-side with line 49a of FIG. 4A connected to line 49b of FIG. 4B and lines 53a-55a of FIG. 4A connected to corresponding lines 53b-55b of FIG. 4B. The steps S1-S6 (FIG. 4A) initialize and check operation of camera 18, modules 37, 41 and PLC 42. If the systems operates properly the program proceeds to step S7; and if the system is not properly initialized the program jumps to step 4000 of FIG. 7 where program restart is tried. If the program restarts properly (FIG. 7) in five tries or less, the program resumes operation at step S5 (FIG. 4A). If the program cannot be started the equipment is shut down.

During program operation edge E (FIG. 2) is observed by camera 18 while the chuck 13 rotates slowly (step S10, FIG. 4A) and twelve characters (steps S15-S20) which indicate edge position are read from camera 18 and converted from ASCII code into decimal code for use by PLC 42.

The first portion of the program of FIG. 4A (flow chart steps S1 to S7) sets up camera 18 and checks camera operation. If camera operation and operating procedures are correct instructions are transferred from PLC 42 to module 41 and examined in steps S8, S9. As part 17 is being oriented in chuck 13 data is read from the camera and converted from ASCII into decimal values (step S17) until a total of twelve characters have been received by PLC 42. The characters are transferred into a decimal expression in step S26 (FIG. 4B) and the validity of the decimal expression is checked in step S27. When part 17 is no longer being oriented in chuck 13 the computer program transfers into the routine of FIG. 5 following step S10 (FIG. 4A).

In routine 500, step S33 (FIG. 5), PLC 42 (FIG. 3) checks to make sure that at least nine pictures of part 17 (FIG. 1) have been taken from camera 18. If less than nine pictures have been taken, in step S33 PLC 42 switches to error routine 4010 (FIG. 8). When at least nine pictures have been received from camera 18, the edge location values are averaged in step S40 (FIG. 5). In step S43 a standard deviation of the edge values is calculated and in step S46 (FIG. 5) the edge location values are checked against the standard deviation. If an irregularity in the surface of part 17 (FIG. 1), or other problem should cause large variations in edge values these values are discarded and corrective measures are taken.

If an incorrect procedure is detected during the time data (step S11) is read from camera 18, PLC 42 switches to an error routine 4040 as shown in FIG. 10. If incorrect or inconsistent data is detected at step S14 (FIG. 4A), PLC 42 switches to error routine 4010 which is shown in FIG. 8.

If the decimal expression of step S26 (FIG. 4B) is incorrect the program checks to see if the part 17 is not in view (NIV) due to an object being positioned between the part and the camera, or due to improper orientation of the camera, etc. If it is determined that the part is not in view the program jumps to error routine 4010 of FIG. 8.

The present invention uses noncontact sensing of alignment of a workpiece in a machining apparatus by using a camera to viewing the edge of the workpiece as the workpiece is rotated. The location of the workpiece edge is compared to a predetermined location as the workpiece rotates to determine if the workpiece is properly positioned in the machining apparatus.

Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modification and variation may be made without departing from what is regarded to be the subject matter of the invention.