SURFACE FINISH QUALITY EVALUATION SYSTEM AND METHOD
A surface evaluation system that includes one or more vision systems that generate target surface data during evaluation of a surface, the one or more vision systems comprising two or more of: at least one light, a camera, a structured light camera, a laser scanner and a 3D scanner.
1 . A method, comprising:
generating instructions to control an automated surface finishing system to apply a material to a target surface;
controlling one or more of a distance and an angle of a light relative to the target surface;
receiving one or more images of the target surface captured by a camera while the light is illuminating the target surface at an incident angle relative to the target surface;
processing the one or more images to identify a feature in the image that indicates a defect in the target surface; and
identifying a rework area based on a location of the feature in the image.
2 . The method of claim 1 , further comprising:
generating a task list for an operator that includes the rework area.
3 . The method of claim 1 , further comprising:
identify the rework area on the target surface for an operator using augmented reality system, wherein the augmented reality system comprises one or more of: screens, projectors, lasers, and augmented glasses.
4 . The method of claim 1 , further comprising:
directing a light at the rework area on the target surface;
continuously monitor a finish quality of the target surface by processing further images captured by the camera; and
changing a color of the light to indicate when the rework area has achieved a desired finish quality.
5 . The method of claim 1 , further comprising:
generating an annotated image visually highlighting to an operator the rework area as feedback.
6 . The method of claim 1 , further comprising:
generating a toolpath and parameters of an automated surface finishing system based on the rework area.
7 . The method of claim 1 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system;
the feature comprises a shadow in the image; and
the method further comprises:
determining a high spot in the target surface based on the shadow; and
generating instructions to control the positioning system and the sanding end effector to cause the sanding end effector to sand down the high spot.
8 . The method of claim 1 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system;
the feature comprises a shadow in the image; and
the method further comprises:
determining a low spot in the target surface based on the shadow; and
generating instructions to control the positioning system and the sanding end effector to cause the sanding end effector to avoid sanding down the low spot.
9 . The method of claim 1 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system;
the feature comprises a shadow in the image; and
the method further comprises:
as the target surface is being sanded down by the sanding end effector, processing further images to determine whether the target surface meets a threshold for surface quality; and
generating instructions to control a positioning system and the sanding end effector coupled to the positioning system to end sanding in response to determining the target surface meets the threshold.
10 . A method, comprising:
controlling a position of a scanner relative to a target surface;
receiving, three-dimensional topography information of the target surface captured by the scanner;
processing the three-dimensional topography information to determine a surface profile of the target surface; and
generating a toolpath and parameters for an automated surface finishing system based on the surface profile.
11 . The method of claim 10 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system; and
the method further comprises:
determining a high spot in the target surface based on the surface profile; and
generating instructions to control the automated surface finishing system to cause the sanding end effector to sand down the high spot.
12 . The method of claim 10 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system; and
the method further comprises:
determining a low spot in the target surface based on the surface profile; and
generating instructions to control the positioning system and the sanding end effector to cause the sanding end effector to avoid sanding down the low spot.
13 . The method of claim 10 , wherein:
the automated surface finishing system comprises a positioning system and a sanding end effector coupled to the positioning system; and
the method further comprises:
as the target surface is being sanded down the sanding end effector, processing further three-dimensional topography information to determine whether the target surface meets a threshold for surface quality; and
generating instructions to control the positioning system and the sanding end effector to end sanding in response to determining the target surface meets the threshold.
14 . A surface quality evaluation system comprising:
a frame having a base-bars to define a frame base that frames an area of a target surface;
top-bars that define a frame top;
side-bars extending from corners of the frame base to define frame sidewalls and couple with the top-bars;
a first light and a second light in different orientations to light up the area;
one or more cameras to capture images of the area; and
a display device to present results of an image analysis of the images to a user.
15 . The surface quality evaluation system of claim 14 , further comprising:
shields to create a light box for controlling lighting of the target surface.
16 . The surface quality evaluation system of claim 14 , wherein:
the first light is coupled at the frame top.
17 . The surface quality evaluation system of claim 14 , wherein:
the second light is coupled at a frame sidewall.
18 . The surface quality evaluation system of claim 14 , wherein:
the first light comprises a first light array;
the second light comprises a second light array;
lights of the first light array are selectively illuminated; and
lights of the second light array are selectively illuminated.
19 . The surface quality evaluation system of claim 14 , further comprising:
one or more scanners to capture three-dimensional topography information of the target surface.
20 . The surface quality evaluation system of claim 14 , wherein the display device further outputs feedback to the user, the feedback including one or more of:
rework areas of the target surface;
instructions on finish parameters to improve surface finish quality; and
alert when a specified surface finish quality is achieved.