Vision system with automatic calibration
A vision system may include a first camera and a second camera mounted for stereoscopic monitoring of a work environment, a support platform for support of a workpiece in the work environment, a first reference plate operably coupled to the support platform to provide a first frame of reference for three dimensional location of objects in the work environment, a power tool operable in the work environment under control of a tool controller, and a motion monitor operably coupled to the first and second cameras to determine location of the tool in the work environment based on a comparison of a reference point on the tool to a position of reference points on the reference plate. A perspective view of the support platform by the first and second cameras may be changeable, and the system may further include a second reference plate to define a second frame of reference for three dimensional location of objects responsive to the perspective view of the support platform being changed.
1. A vision system comprising:
a first camera and a second camera mounted for stereoscopic monitoring of a work environment;
a support platform for support of a workpiece in the work environment;
a first reference plate operably coupled to the support platform to provide a first frame of reference for three dimensional location of objects in the work environment;
a power tool operable in the work environment under control of a tool controller; and
a motion monitor operably coupled to the first and second cameras to determine location of the tool in the work environment based on a comparison of a reference point on the tool to a position of reference points on the reference plate,
wherein a perspective view of the support platform by the first and second cameras is changeable, and
wherein the system further comprises a second reference plate to define a second frame of reference for three dimensional location of objects responsive to the perspective view of the support platform being changed.
2. The vision system of claim 1 , wherein the first and second cameras are static and the support platform is dynamic.
3. The vision system of claim 2 , wherein the first reference plate lies in a first plane and the second reference plate lies in a second plane, and wherein an angular difference between the first and second planes is substantially equal to an amount of rotation of the support platform to change the perspective view.
4. The vision system of claim 1 , wherein the first reference plate includes a first pattern of reference points thereon and the second reference plate includes a second pattern of reference points thereon, the first and second patterns being different.
5. The vision system of claim 4 , wherein the first and second patterns are defined by different geometric shapes.
6. The vision system of claim 5 , wherein the different geometric shapes comprise different types of triangles.
7. A vision system comprising:
a first camera and a second camera mounted for stereoscopic monitoring of a work environment;
a support platform for support of a workpiece in the work environment;
a reference plate operably coupled to the support platform to provide a frame of reference for three dimensional location of objects in the work environment;
a power tool operable in the work environment under control of a tool controller; and
a motion monitor operably coupled to the first and second cameras to determine location of the tool in the work environment based on a comparison of a reference point on the tool to a position of reference points on the reference plate,
wherein the reference plate comprises at least four reference points distributed thereon, and
wherein the motion monitor is configured to perform automatic configuration based on the at least four reference points using the same spectrum used to determine the location of the tool.
8. The vision system of claim 7 , wherein the same spectrum comprises infrared spectrum.
9. The vision system of claim 7 , wherein the automatic configuration is performed during object tracking associated with determining the location of the tool.
10. The vision system of claim 7 , wherein three of the reference points form a triangle, and a fourth reference point is located spaced apart from a nearest leg of the triangle such that the at least four reference points form a quadrilateral.
11. A vision system comprising:
a first camera and a second camera mounted for stereoscopic monitoring of a work environment;
a support platform for support of a workpiece in the work environment;
a reference plate operably coupled to the support platform to provide a frame of reference for three dimensional location of objects in the work environment;
a power tool operable in the work environment under control of a tool controller; and
a motion monitor operably coupled to the first and second cameras to determine location of the power tool in the work environment based on a comparison of a reference point on the tool to a position of reference points on the reference plate,
wherein the motion monitor is configured to monitor the location of the power tool relative to a movement zone defining a volume in three dimensional space.
12. The vision system of claim 11 , wherein the movement zone defines a cylindrical volume of permissible tool locations as the power tool approaches an object on the workpiece.
13. The vision system of claim 11 , wherein the movement zone is generated base on a learning mode in which the movement zone is defined based on a plurality of monitored tool movements.
14. The vision system of claim 13 , wherein the learning mode has a quality threshold relative to data monitored prior to allowing the movement zone to be generated.
15. The vision system of claim 13 , wherein the learning mode has a quantity threshold relative to data monitored prior to allowing the movement zone to be generated.
16. The vision system of claim 11 , wherein the power tool is disabled responsive to a determination that the power tool violates a boundary of the movement zone.
17. The vision system of claim 11 , wherein feedback regarding operation of the power tool is provided to an operator responsive to a determination that the power tool violates a boundary of the movement zone.
18. The vision system of claim 17 , wherein the boundary is defined as a maximum allowable deviation from an average or best fit path of the power tool.
19. The vision system of claim 11 , wherein selected data stored during determining tool location is used for determining the movement zone.
20. The vision system of claim 11 , wherein a linear indicator is provided on the power tool, the linear indicator being detectable by the first and second cameras to define a direction of extension of a socket or adapter of the power tool.