English:
[0001] Embodiments of the present disclosure generally relate to determining thickness of three-dimensional (3D) object coatings. More particularly, embodiments of the present disclosure relate to determining thickness of protective coatings for turbine blades and other components exposed to corrosive environments.
[0002] Aerospace components including turbine vanes and blades are fabricated from nickel and cobalt-based superalloys Supera!!oy protection during engine operation employs a plurality of layers, including a stable oxide scale that is dense, adheres to the surface or surfaces of the component, and is stable at high temperatures up to about 1900 °C. Various barrier coatings, including thermal barrier coatings (TBCs), can be used to inhibit oxidation and corrosion of the aerospace components. Various materials are employed to form these corrosion- resistant coatings, such as native-grown oxides include Cr203 for hot corrosion protection and AI2O3 for oxidation resistance. TBCs and other barrier coatings can be deposited using either e-beam PVD or thermal spray. Deposited TBCs include yttria-stabilized zirconia, gadolinium zirconate, tantalum-yttrium zirconium oxides, and other mixed zirconate, baifnate, silicate, and aluminate compounds. However, measuring TBC thickness on three-dimensional (3D) objects may be destructive, inaccurate, costly, and time-consuming.
[0003] Thus, there remains a need in the art for measuring coating thicknesses of 3D objects with non-destructive imaging methods.
[0004] in one embodiment, a method of determining a thickness of an object coating is provided. The method includes, in a non-destructive measurement device having at least one image sensor system, positioning an uncoated surface of an object in a field view of the at least one image sensor system. The object has one or more surfaces. A first 3D image of the uncoated surface is collected without chemically or physically changing the one or more surfaces of the object. The first 3D image corresponds to a first surface profile of the uncoated surface. A coated surface of the object is positioned in the field view of the at least one image sensor system. A second 3D image of the coated surface is collected without chemically or physically changing the one or more surfaces of the object. The second 3D image corresponds to a second surface profile of the coated surface. The first 3D image and the second 3D image are analyzed.
[0005] In another embodiment, a method of determining a thickness of an object coating is provided. The method includes in a non-destructive measurement device having at least one image sensor system, positioning a surface of an object in a field view of the at least one image sensor system. The object has one or more surfaces and the surface having a uncoated portion and a coated portion. A 3D image of the surface is collected without chemically or physically changing the one or more surfaces of the object. The 3D image corresponds to a first surface profile of the uncoated portion and a second surface profile of the coated portion. The 3D image is analyzed.
[0006] In yet another embodiment, a non-destructive measurement device is provided. The non-destructive measurement device includes a body, a stage assembly disposed in the body having a stage configured to retained an object and a coordinate grid, an image sensor assembly disposed in the body, an alignment mechanism disposed in the body, and a controller. Each of the one or more image sensor systems has an illumination unit, one or more image sensors, and a Quick Response (QR) code reader. The alignment mechanism operable to align position the object at an alignment position on the coordinate grid. The alignment position corresponds to the QR code of the object. The controller is coupled to the stage assembly, the image sensor assembly, and the alignment mechanism. The controller is interfaced with a coating system and controls automation integration with the coating system via a system controller of the coating system. The controller is configured to instruct the one or more image sensor systems to collect one or more 3D images of one or more surfaces of the object analyze the one or more 3D images to obtain a thickness of a coating of the object.
[0007] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.
[0008] Figure 1 is a schematic view of a coating system having an at least one integrated non-destructive measurement device according to an embodiment.
[0009] Figure 2A is a schematic cross-sectional view of a non-destructive measurement according to an embodiment.
[0010] Figure 2B is a schematic top view of a non-destructive measurement according to an embodiment.
[0011] Figure 2C is a schematic view of an image sensor system according to an embodiment.
[0012] Figure 3 is a flow diagram of a sub-method of a non-destructive measurement method for determining coating thickness of a 3D object according to an embodiment.
[0013] Figure 4 is a flow diagram of a sub-method of a non-destructive measurement method for determining coating thickness of a 3D object according to an embodiment.
[0014] Figure 5 is a flow diagram of a method for determining coating thickness of a 3D object.
[0016] Embodiments described herein relate to a non-destructive measurement device measurement device and a non-destructive measurement method for determining coating thickness of a three-dimensional (3D) object.
[0017] Figure 1 is a schematic view of a coating system 100 having an at least one integrated non-destructive measurement device 102. Additionally, the non destructive measurement device 102 may be provided as a standalone device unattached and remote from the system 100. The system 100 and the integrated non-destructive measurement device 102 are utilized for coating 3D objects and measuring coating thicknesses on 3D objects with non-destructive imaging methods. It is to be understood that the system described below is an exemplary system and other systems, including systems from other manufacturers, may be used with or modified to accomplish aspects of the present disclosure. The system 100 includes one or more non-destructive measurement devices 102 and one or more of coating modules 104 coupled to a transfer chamber 106. In one embodiment, which can be combined with other embodiments described herein, the system 100 includes one or more processing modules 108 coupled to the transfer chamber 106. The one or more coating modules 104 are adapted for coating 3D objects. In one embodiment, which can be combined with other embodiments described herein, the 3D objects include aerospace components, such as turbine vanes and blades. In another embodiment, which can be combined with other embodiments described herein, the coatings are barrier coatings, such as thermal barrier coatings (TBCs). The one or more processing modules are adapted for processing the 3D objects, and the like. The transfer chamber 106 houses a transfer mechanism 110 used to transfer 3D objects between the measurement devices 102, coating modules 104, and processing modules 108.
[0019] In operation, the system controller 112 enables feedback from each module and measurement device 102 to optimize 3D object throughput. The system controller 112 comprises a central processing unit (CPU) 114, a memory 118, and a support circuit 118. The CPU 114 may be one of any form of a general purpose computer processor that can be used in an industrial setting. The support circuit 118 is conventionally coupled to the CPU 114 and may comprise cache, clock circuits, input/output subsystems, power supplies, and the like. The software routines, when executed by the CPU 114, transform the CPU into a specific purpose computer (controller). The software routines may also be stored and/or executed by a second controller (not shown) that is located remotely from the measurement device 102.
[0020] Figure 2A is a schematic cross-sectional view of a measurement device 102. Figure 2B is a schematic top view of the measurement device 102. Figure 2C is a schematic view of an image sensor system 212. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for non-destructive methods of measuring coating thicknesses of 3D objects. The measurement device 102 includes a body 200, a stage assembly 202, an image sensor assembly 204, an alignment mechanism 206, and controller 208. The stage assembly 202 includes a stage 210 configured to retain an object 101. In one embodiment, which can be combined with other embodiments described herein, the object 101 is a three-dimensional (3D) object. In another embodiment, which can be combined with other embodiments described herein, the stage 210 is a goniometric stage and/or optical stage. The stage 210 is configured to rotate the object 101 about at least one of an x-axis, y-axis, and z-axis of the stage 210 to position one or more of surfaces 103 of the object 101 in relation to one or more image sensor systems 212 of the image sensor assembly 204. The stage 210 includes an actuator 222 that moves the stage 210 between a measurement position (as shown) and a transfer position. The actuator 222 facilitates object transfer to and from the measurement device 102 through an opening 224 formed though the body 200 and sealable by a door 226. In one embodiment, which can be combined with other embodiments described herein, the actuator 222 is operable to rotate the object 101 about at least one of the x~axis, y~axis, and z-axis of the stage 210. The stage 210 includes a coordinate grid 214 disposed thereon. The coordinate gird 214 is utilized for the non-destructive methods of measuring coating thicknesses of 3D objects described herein.
[0021] The controller 208 is coupled to the stage assembly 202, the one or more image sensor systems 212, and the alignment mechanism 206. The controller 208 includes a central processing unit (CPU) 216, a memory 218, and support circuits (or I/O) 220. The CPU 216 is one of any form of computer processors used in industrial settings for controlling various processes and hardware (e.g., goniometers, motors, and other hardware) and/or monitoring the processes (e.g., processing time and object 101 position). The memory 218 is connected to the CPU 216. The memory 218 is one or more of a readily available memory, such as random access memory (RAM), read only memory (ROM), floppy disk, hard disk, or any other form of digital storage, local or remote. Software instructions and data are coded and stored within the memory 218 for instructing the CPU 216. The support circuits 220 are also connected to the CPU 216 for supporting the processor in a conventional manner. The support circuits include conventional cache, power supplies, clock circuits, input/output circuitry, subsystems, and the like. A program (or computer instructions), which may be referred to as an imaging program, is readable by the controller determines which tasks are performabie on the object 101. The program is software readable by the controller and includes code to monitor and control, for example, the processing time and object 101 position. In one embodiment, which can be combined with other embodiments described herein, the memory 218 includes image acquisition software, image analysis software, image numbering software to determine position and orientation of the object 101 , a data base with part numbers and image information, each number corresponding to an object 101 and each image information corresponding to the object 101 of the part number, and/or software that outputs thickness of the object 101 and/or one or more surfaces 103 of the object 101.
[0022] The image sensor assembly 204 includes the image sensor systems 212. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 are in fixed positions oriented toward, i.e. , facing the field of view 211 of the image sensor systems 212, a surface of the one or more surfaces 103 of the object 101 Therefore, rotation of the stage 210 and movement of the one or more image sensor systems 212 are not required for the non-destructive imaging methods described herein. In another embodiment, which can be combined with other embodiments described herein, the imaging sensor assembly 204 includes only one image sensor system 212 and the rotation of the stage 210 is utilized to position each of the one or more surfaces 103 in an orientation toward the image sensor system 212. In yet another embodiment, as shown, which can be combined with other embodiments described herein, the one or more image sensor systems 212 are operable to be oriented toward each of the one or more surfaces 103. For example, the one or more image sensor systems 212 are coupled a track 228 disposed in the body 200 and around a circumference 231 of the stage 210. In one embodiment, which can be combined with other embodiments described herein, the track 228 is a rail or cable. Each of the one or more image sensor systems 212 includes an actuator 230 that move the one or more image sensor systems 212 along the track 228 around the circumference 231 of the stage 210.
[0023] In embodiments described herein, which can be combined with other embodiments described herein, multiple 3D objects are coated utilizing the system 100 and the coating thickness of each of the multiple 3D objects are measured utilizing at least one non-destructive measurement device 102. The multiple 3D objects include different pluralities of 3D objects and the alignment mechanism 206 is operable to position each 3D object of each plurality of the different pluralities of 3D objects in substantially the same positon on the stage 210. Measuring the coating thickness each 3D object of each plurality of the different pluralities of 3D objects from substantially the same positon allows for part coordinates each 3D object of each plurality of the different pluralities of 3D objects to be in substantially the same positon. In one embodiment, which can be combined with other embodiments described herein, the alignment mechanism 206 includes an actuated arm mechanism 232 and a gripper 234. The actuated arm mechanism 232 and the gripper 234 allows the alignment mechanism 206 to capture the object 101 on the stage 210 and align the object 101 by positioning the object 101 at an alignment position 236 of coordinate gird 214 of the stage 210.
[0024] Referring to Figure 1 , the system 100 having the one or more integrated non-destructive measurement devices 102 may be utilized in concurrently with a non-destructive measurement method 500 for determining coating thickness of a 3D object. Multiple 3D objects are coated utilizing the system 100 and the coating thickness of each of the multiple 3D objects are measured utilizing at least one non destructive measurement device 102. For example, an uncoated 3D object of a one of the pluralities of 3D objects is measured in a first measurement device and a coated 3D object of a one of the pluralities of 3D objects is measured in a second measurement device of the one or more integrated non-destructive measurement devices 102. Concurrently, 3D objects are coated in the one or more of coating modules 104. The system controller 112 controls movements of the transfer mechanism 110, transferring 3D objects to and from the measurement devices 102 and coating modules 104, and is interfaced with the controller 208 for performing the method 500.
[0025] The image sensor system 212 includes an illumination unit 201 and one or more image sensors 203. In one embodiment, which can be combined with other embodiments described herein, the one or more image sensors 203 are cameras. In a first configuration, also known as a time-of-flight configuration, the illumination unit 201 is configured to project one or more pulses of light, such as infrared light, on the one or more surfaces 103 of the object 101 without chemically or physically changing the one or more surfaces 103 of the object 101. Each of the one or more image sensors 203 coupled to the controller 208 having a timing mechanism determine the time-of-flight of the one or more pulses of light from the one or more surfaces 103 of the object 101 to each of the one or more image sensors 203. Determining the time-of-flight of the one or more pulses of light from the one or more surfaces 103 of the object 101 to each of the one or more image sensors 203 allows for z-axis positions (zi, Z2, . . . ,zn) on a z-axis 207 of the one or more surfaces 103 to be determined to generate a 3D image of the one or more surfaces 103.
[0027] As shown in Figure 2C, the surface 103 of the object 101 has at least one part coordinate 213. Each part coordinate 213 includes an x-position (xi, X2, . . . ,xn) on an x~axis 205 and a y-position (yi, i, . . . ,yn) on an y-axis 209. The x-axis 205, y-axis 209, and z-axis 207 are relative the image sensor system 212 facing the surface 103. Thus, each of the one or more surfaces 103 has at least one part coordinate on the x-axis 205 and the y-axis 209 of the coordinate gird 214. The image sensor system 212 includes a Quick Response (QR) code reader 215 operable to read a QR code 217 disposed on the object 101. Each plurality of 3D objects of the pluralities of 3D objects has a different QR code 217 The image sensor system 212 is coupled to the controller 208 such that the QR code is provided to controller 208 The controller instructs the image sensor system 212 to determine the z-axis positions of each part coordinate 213 of the object 101 corresponding to the QR code 217.
[0028] Figure 3 is a flow diagram of a sub-method 300 of non-destructive measurement method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the sub-method 300. At operation 301 , the QR code 217 of an uncoated object 101 is read by the QR reader 215 and the aligned on the stage 210 at the alignment position 236 corresponding to the QR code 217. At optional operation 302, the image sensor system 212 determines the z-axis position of each part coordinate 213 of a first uncoated surface of the object 101. At operation 303, a 3D image of the first uncoated surface of the object 101 is collected by the image sensor system 212. At operation 304, optional operation 302 and operation 303 are repeated for a predetermined number of uncoated surfaces. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 in fixed positions facing a surface of the one or more surfaces 103 of the object 101. Therefore, the z-axis positions are determined and 3D images are collected without rotating the object 101. In other embodiments, which can be combined with other embodiments described herein, the object 101 is rotated by the stage 210 and/or the one or more image sensor systems 212 are moved around the circumference 231 of the stage 210. At operation 305, the uncoated object 101 is removed from the stage 210 and coated. At operation 306, operations 301 -304 are repeated for the coated object 101.
[0029] Figure 4 is a flow diagram of a sub-method 400 of non-destructive measurement method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the sub-method 400. At operation 401 , the QR code 217 of an object 101 is read by the QR reader 215 and the aligned on the stage 210 at the alignment position 236 corresponding to the QR code 217. The object 101 includes one or more surfaces 103. At optional operation 402, the image sensor system 212 determines the z-axis position of each part coordinate 213 of the one or more surfaces. At operation 403, a 3D image of each of the one or more surfaces 103 is collected. In one embodiment, which can be combined with other embodiments described herein, at least one surface of the one or more surfaces 103 is uncoated and at least one surface of the one or more surfaces is coated. In another embodiment, which can be combined with other embodiments described herein, at least one surface of the one or more surfaces 103 has a coated portion and an uncoated portion. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 in fixed positions facing the one or more surfaces 103 of the object 101. Therefore, the z-axis positions are determined and 3D images are collected without rotating the object 101. In other embodiments, which can be combined with other embodiments described herein, the object 101 is rotated by the stage 210 and/or the one or more image sensor systems 212 are moved around the circumference 231 of the stage 210.
[0030] Figure 5 is a flow diagram of a method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the method 500. At operation 501 , one of the sub-method 300 and the sub-method 400 are performed to collect one or more 3D images. In one embodiment, which can be combined with other embodiments described herein, one of the sub-method 300 and the sub-method 400 are performed to collect at least one first 3D image of an uncoated surface of the object 101 and at least one second 3D image of a coated surface of the object 101. In the embodiment, the uncoated surface and coated surface correspond to a same surface of the one or more surfaces 103 of the object 101. In another embodiment, which can be combined with other embodiments described herein, the sub-method 400 collects at least one first 3D image of a surface having an uncoated portion and a coated portion. The first 3D image include z-axis positions (zi, zz, . . . ,zn) on the z-axis 207 of the surface of the first 3D image. The second 3D image include z-axis positions (zi, Z2, . . . ,zn) on the z-axis 207 of the surface of the second 3D image.
[0031] At optional operation 502, the one or more 3D images are mirrored in the z-axis 207. The mirrored one or more 3D images correspond to surface profiles. In one embodiment, which can be combined with other embodiments described herein, the first 3D image is mirrored in the z-axis 207 such that a mirrored 3D image corresponds to a first surface profile of the uncoated surface. In another embodiment, which can be combined with other embodiments described herein, the first 3D image is mirrored in the z-axis 207 such that a mirrored first 3D image corresponds to the first surface profile of the uncoated portion and a second surface profile of the coated portion of the surface. A mirrored second 3D image corresponds to the second surface profile of the coated surface. At operation 503, outliers of the one or more 3D images are removed. In one embodiment, which can be combined with other embodiments described herein, outliers the first 3D image and the second 3D image are removed. At optional operation 504, areas of the one or more 3D images are selected for operations 505-507. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are selected for operations 505-507. At operation 505, the one or more 3D images are filtered. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are filtered. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are filtered utilizing a Gaussian filter. Filtering the first 3D image and the second 3D image removes one of image noise and surface roughness.
[0032] At optional operation 506, the one or more 3D images are overlapped. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are overlapped. When the first 3D image includes the uncoated portion and the coated portion it is not necessary to overlap the first 3D image and the second 3D image because the second 3D image is not collected. At operation 507, the surface profiles of the one or more images are subtracted. In one embodiment, which can be combined with other embodiments described herein, the second surface profile is subtracted first surface profile to obtain a thickness of the coating. At optional operation 508, operations 502-507 are repeated. In one embodiment, which can be combined with other embodiments described herein, operations 502-507 are repeated for at least one subsequent first 3D image and at least one subsequent second 3D image collected from one of the sub-method 300 and the sub-method 400. In another embodiment, which can be combined with other embodiments described herein, operations 501 - 508 are repeated to collect and analyze one or more 3D images of additional surfaces.
[0033] In summation, a non-destructive measurement device measurement device and a non-destructive measurement method for determining coating thickness of a three-dimensional (3D) object are provided. The utilization non destructive image collection methods in addition to the time-of-flight configuration and structured light configuration of the image sensor system allow for the determining coating thickness of a 3D object without chemically or physically changing the one or more surfaces of the object.
[0034] While the foregoing is directed to examples of the present disclosure, other and further examples of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow

中文:
[0001]本公开内容的实施方式大致涉及确定三维(three-dimensional;3D)物体涂层的厚度。更特别地,本公开内容的实施方式涉及确定用于暴露于腐蚀性环境的涡轮机叶片和其他部件的保护涂层的厚度。
[0002]航空部件,包括涡轮机轮叶和叶片,由镍和钴基超合金制成。在发动机操作期间的超合金保护采用多个层,包括稳定氧化皮,所述稳定氧化皮是致密的,所述稳定氧化皮附着到部件的一个或多个表面,并且在高达1900°C的高温下是稳定的。各种阻挡涂层,包括热障涂层(thermal barrier coating;TBC),可用于抑制航空部件的氧化和腐蚀。采用各种材料来形成这些耐腐蚀涂层,诸如自然地生长的氧化物,其包括用于热腐蚀保护的Cr2O3和用于耐氧化的Al2O5。可使用电子束物理气相沉积(physical vapor deposition;PVD)或热喷涂来沉积TBC和其他阻挡涂层。沉积的TBC包括氧化钇稳定的氧化锆、锆酸钆、钽钇锆氧化物,以及其他混合的锆酸盐、铪酸盐、硅酸盐和铝酸盐化合物。然而,测量三维(3D)物体上的TBC厚度可能是破坏性的、不准确的、昂贵的且耗时的。
[0003]因此,本领域中仍需要用非破坏性成像方法来测量3D物体的涂层厚度。
[0004]在一个实施方式中,提供了一种确定物体涂层的厚度的方法。所述方法包括在具有至少一个图像传感器系统的非破坏性测量装置中,将物体的未涂覆表面定位在至少一个图像传感器系统的视场中。物体具有一个或多个表面。在不化学地或物理地改变物体的一个或多个表面的情况下,采集未涂覆表面的第一3D图像。第一3D图像与未涂覆表面的第一表面轮廓相对应。将物体的涂覆表面定位在至少一个图像传感器系统的视场中。在不化学地或物理地改变物体的一个或多个表面的情况下,采集涂覆表面的第二3D图像。第二3D图像与涂覆表面的第二表面轮廓相对应。分析第一3D图像和第二3D图像。
[0005]在另一个实施方式中,提供了一种确定物体涂层的厚度的方法。所述方法包括在具有至少一个图像传感器系统的非破坏性测量装置中,将物体的表面定位在至少一个图像传感器系统的视场中。物体具有一个或多个表面,并且所述表面具有未涂覆部分和涂覆部分。在不化学地或物理地改变物体的一个或多个表面的情况下,采集所述表面的3D图像。3D图像与未涂覆部分的第一表面轮廓和涂覆部分的第二表面轮廓相对应。分析3D图像。
[0006]在又一个实施方式中,提供了一种非破坏性测量装置。所述非破坏性测量装置包括:主体;平台组件,所述平台组件设置在主体中,所述平台组件具有被配置为保持物体的平台和坐标网格;图像传感器组件,所述图像传感器组件设置在主体中;对准机构,所述对准机构设置在主体中;和控制器。一个或多个图像传感器系统中的每一个具有照明单元、一个或多个图像传感器和快速响应(QR)码读取器。对准机构是可操作的以将物体对准至坐标网格上的对准位置。对准位置与物体的QR码相对应。控制器耦接到平台组件、图像传感器组件和对准机构。控制器与涂覆系统对接,并且经由涂覆系统的系统控制器控制与涂覆系统的自动化集成。控制器被配置为指示一个或多个图像传感器系统采集物体的一个或多个表面的一个或多个3D图像,分析一个或多个3D图像以获得物体的涂层的厚度。
[0007]为了可详细地理解本公开内容的上述特征的方式,可参考实施方式来获得上文简要地概述的本公开内容的更详细的描述,所述实施方式中的一些示于附图中。然而,应注意,附图仅示出了示例性实施方式,并且因此不应视为对其范围的限制,因为附图可允许其他等效实施方式。
[0008]图1是根据实施方式的具有至少一个集成的非破坏性测量装置的涂覆系统的示意图。
[0009]图2A是根据实施方式的非破坏性测量装置的示意性横截面图。
[0010]图2B是根据实施方式的非破坏性测量装置的示意性俯视图。
[0011]图2C是根据实施方式的图像传感器系统的示意图。
[0012]图3是根据实施方式的用于确定3D物体的涂层厚度的非破坏性测量方法的子方法的流程图。
[0013]图4是根据实施方式的用于确定3D物体的涂层厚度的非破坏性测量方法的子方法的流程图。
[0014]图5是用于确定3D物体的涂层厚度的方法的流程图。
[0016]本文中描述的实施方式涉及一种用于确定三维(3D)物体的涂层厚度的非破坏性测量装置和非破坏性测量方法。
[0017]图1是具有至少一个集成的非破坏性测量装置102的涂覆系统100的示意图。另外地,非破坏性测量装置102可被提供为未附接至系统100并远离系统100的独立装置。系统100和集成的非破坏性测量装置102用于涂覆3D物体并通过非破坏性成像方法测量3D物体上的涂层厚度。应理解,下文描述的系统是示例性系统,并且其他系统(包括来自其他制造商的系统)可与本公开内容的方面一起使用,或者被修改以完成本公开内容的方面。系统100包括耦接到传送腔室106的一个或多个非破坏性测量装置102以及涂覆模块104中的一个或多个。在可与本文中描述的其他实施方式组合的一个实施方式中,系统100包括耦接到传送腔室106的一个或多个处理模块108。一个或多个涂覆模块104适于涂覆3D物体。在可与本文中描述的其他实施方式组合的一个实施方式中,3D物体包括航空部件,诸如涡轮机轮叶和叶片。在可与本文中描述的其他实施方式组合的另一个实施方式中,涂层是阻挡涂层,诸如热障涂层(TBC)。一个或多个处理模块适于处理3D物体和类似者。传送腔室106容纳传送机构110,传送机构110用于在测量装置102、涂覆模块104和处理模块108之间传送3D物体。
[0019]在操作中,系统控制器112使得来自每个模块和测量装置102能够进行反馈以优化3D物体吞吐量。系统控制器112包括中央处理单元(CPU)114、存储器116和支持电路118。CPU114可为可用于工业环境中的任何形式的通用计算机处理器中的一种。支持电路118常规地耦接到CPU 114,并且可包括高速缓存、时钟电路、输入/输出子系统、电源等。当由CPU 114执行时,软件例程将CPU变换成专用计算机(控制器)。软件例程也可由远离测量装置102定位的第二控制器(未示出)存储和/或执行。
[0020]图2A是测量装置102的示意性横截面图。图2B是测量装置102的示意性俯视图。图2C是图像传感器系统212的示意图。在可与本文中描述的其他实施方式组合的一个实施方式中,测量装置102用于测量3D物体的涂层厚度的非破坏性方法。测量装置102包括主体200、平台组件202、图像传感器组件204、对准机构206和控制器208。平台组件202包括被配置为保持物体101的平台210。在可与本文中描述的其他实施方式组合的一个实施方式中,物体101是三维(3D)物体。在可与本文中描述的其他实施方式组合的另一个实施方式中,平台210是测角(goniometric)平台和/或光学平台。平台210被配置为使物体101围绕平台210的x轴、y轴和z轴中的至少一者旋转,以相对于图像传感器组件204的一个或多个图像传感器系统212定位物体101的表面103中的一个或多个。平台210包括致动器222,致动器222使平台210在测量位置(如图所示)与传送位置之间移动。致动器222有助于通过穿过主体200形成并可被门226密封的开口224向测量装置102传送物体和从测量装置102传送物体。在可与本文中描述的其他实施方式组合的一个实施方式中,致动器222是可操作的以使物体101围绕平台210的x轴、y轴和z轴中的至少一个旋转。平台210包括设置在所述平台上的坐标网格214。坐标网格214用于测量本文中描述的3D物体的涂层厚度的非破坏性方法。
[0021]控制器208耦接到平台组件202、一个或多个图像传感器系统212和对准机构206。控制器208包括中央处理单元(CPU)216、存储器218和支持电路(或I/O)220。CPU 216是在工业环境中使用来控制各种处理和硬件(例如,测角仪、电动机和其他硬件)和/或监测处理(例如,处理时间和物体101位置)的任一形式的计算机处理器。存储器218连接到CPU 216。存储器218是容易获得的存储器中的一个或多个,诸如随机存取存储器(RAM)、只读存储器(ROM)、软盘、硬盘或任何其他形式的数字存储装置(本地或远程)。软件指令和数据被编码并存储在存储器218内来对CPU 216作指示。支持电路220也连接到CPU 216来以常规的方式支持处理器。支持电路包括常规的高速缓存、电源、时钟电路、输入/输出电路、子系统和类似者。可称为成像程序的程序(或计算机指令)可由控制器读取,确定在物体101上可执行哪些任务。程序是可由控制器读取的软件,并且包括代码以监测和控制例如处理时间和物体101位置。在可与本文中描述的其他实施方式组合的一个实施方式中,存储器218包括:图像获取软件、图像分析软件、图像编号软件以确定物体101的位置和取向;具有零件编号和图像信息的数据库,每个编号与物体101相对应并且每个图像信息与该零件编号的物体101相对应;和/或输出物体101的厚度和/或物体101的一个或多个表面103的软件。
[0022]图像传感器组件204包括图像传感器系统212。在可与本文中描述的其他实施方式组合的一个实施方式中,图像传感器组件204包括一个或多个图像传感器系统212中的每一个,图像传感器系统212位于朝向物体101的一个或多个表面103中的表面取向(即,面向图像传感器系统212的视场211)的固定位置处。因此,本文中描述的非破坏性成像方法不需要平台210的旋转和一个或多个图像传感器系统212的移动。在可与本文中描述的其他实施方式组合的另一个实施方式中,成像传感器组件204仅包括一个图像传感器系统212,并且利用平台210的旋转将一个或多个表面103中的每一个定位在朝向图像传感器系统212的取向上。在可与本文中描述的其他实施方式组合的又一个实施方式中,如图所示,一个或多个图像传感器系统212是可操作的以朝向一个或多个表面103中的每一个取向。例如,一个或多个图像传感器系统212与设置在主体200中并围绕平台210的圆周231的轨道228耦接。在可与本文中描述的其他实施方式组合的一个实施方式中,轨道228是导轨或缆线。一个或多个图像传感器系统212中的每一个包括致动器230,致动器230使一个或多个图像传感器系统212沿着轨道228围绕平台210的圆周231移动。
[0023]在可与本文中描述的其他实施方式组合的本文中描述的实施方式中,利用系统100来涂覆多个3D物体,并且利用至少一个非破坏性测量装置102来测量多个3D物体中的每一个的涂层厚度。多个3D物体包括不同的多个3D物体,并且对准机构206是可操作的以将不同的多个3D物体中的每一类多个3D物体中的每个3D物体定位在平台210上的基本上相同的位置。从基本上相同的位置测量不同的多个3D物体中的每一类多个3D物体中的每个3D物体的涂层厚度允许不同多个3D物体中的每一类多个3D物体中的每个3D物体的局部坐标在基本上相同的位置。在可与本文中描述的其他实施方式组合的一个实施方式中,对准机构206包括致动臂机构232和夹持器234。致动臂机构232和夹持器234允许对准机构206在平台210上抓取物体101,并通过将物体101定位在平台210的坐标网格214的对准位置236处来将物体101对准。
[0024]参考图1,具有一个或多个集成的非破坏性测量装置102的系统100可与非破坏性测量方法500一起用于确定3D物体的涂层厚度。利用系统100涂覆多个3D物体,并且利用至少一个非破坏性测量装置102测量多个3D物体中的每一个的涂层厚度。例如,在第一测量装置中测量多个3D物体中的一个的未涂覆3D物体,并且在一个或多个集成非破坏性测量装置102的第二测量装置中测量多个3D物体中的一个的涂覆3D物体。同时,在涂覆模块104中的一个或多个中涂覆3D物体。系统控制器112控制传送机构110的移动、向测量装置102和涂覆模块104传送3D物体和从测量装置102和涂覆模块104传送3D物体,并且与控制器208对接以执行方法500。
[0025]图像传感器系统212包括照明单元201和一个或多个图像传感器203。在可与本文中描述的其他实施方式组合的一个实施方式中,一个或多个图像传感器203是相机。在第一配置(也称为飞行时间配置)中,照明单元201被配置为在不化学地或物理地改变物体101的一个或多个表面103的情况下将一个或多个光脉冲(诸如红外光)投射在物体101的一个或多个表面103上。耦接到具有定时机构的控制器208的一个或多个图像传感器203中的每一个确定一个或多个光脉冲从物体101的一个或多个表面103到一个或多个图像传感器203中的每一个的飞行时间。确定一个或多个光脉冲从物体101的一个或多个表面103到一个或多个图像传感器203中的每一个的飞行时间允许确定一个或多个表面103在z轴207上的z轴位置(z1、z2、......、zn),以生成一个或多个表面103的3D图像。
[0027]如图2C所示,物体101的表面103具有至少一个局部坐标213。每个局部坐标213包括在x轴205上的x位置(x1、x2、......、xn)和在y轴209上的y位置(y1、y2、......、yn)。x轴205、y轴209和z轴207是相对于面向表面103的图像传感器系统212的轴。因此,一个或多个表面103中的每一个具有在坐标网格214的x轴205和y轴209上的至少一个局部坐标。图像传感器系统212包括快速响应(QR)码读取器215,QR码读取器215是可操作的以读取设置在物体101上的QR码217。多个3D物体中的每一类多个3D物体具有不同QR码217。图像传感器系统212耦接到控制器208,使得QR码被提供给控制器208。控制器指示图像传感器系统212确定物体101的与QR码217相对应的每个局部坐标213的z轴位置。
[0028]图3是用于确定3D物体的涂层厚度的非破坏性测量方法500的子方法300的流程图。在可与本文中描述的其他实施方式组合的一个实施方式中,测量装置102用于子方法300。在操作301处,由QR读取器215读取未涂覆物体101的QR码217,并且在平台210上将其对准至与QR码217相对应的对准位置236处。在可选的操作302处,图像传感器系统212确定物体101的第一未涂覆表面的每个局部坐标213的z轴位置。在操作303处,由图像传感器系统212采集物体101的第一未涂覆表面的3D图像。在操作304处,对预定数量的未涂覆表面重复可选的操作302和操作303。在可与本文中描述的其他实施方式组合的一个实施方式中,图像传感器组件204包括一个或多个图像传感器系统212中的每一个,图像传感器系统212位于面向物体101的一个或多个表面103中的表面的固定位置。因此,无需旋转物体101就可确定z轴位置并采集3D图像。在可与本文中描述的其他实施方式组合的其他实施方式中,由平台210旋转物体101和/或使一个或多个图像传感器系统212围绕平台210的圆周231移动。在操作305处,将未涂覆物体101从平台210移除并对其进行涂覆。在操作306处,对涂覆物体101重复操作301至304。
[0029]图4是用于确定3D物体的涂层厚度的非破坏性测量方法500的子方法400的流程图。在可与本文中描述的其他实施方式组合的一个实施方式中,测量装置102用于子方法400。在操作401处,由QR读取器215读取物体101的QR码217,并且在平台210上将其对准至与QR码217相对应的对准位置236处。物体101包括一个或多个表面103。在可选的操作402处,图像传感器系统212确定一个或多个表面的每个局部坐标213的z轴位置。在操作403处,采集一个或多个表面103中的每一个的3D图像。在可与本文中描述的其他实施方式组合的一个实施方式中,一个或多个表面103中的至少一个表面是未涂覆的,并且一个或多个表面中的至少一个表面是涂覆的。在可与本文中描述的其他实施方式组合的另一个实施方式中,一个或多个表面103中的至少一个表面具有涂覆部分和未涂覆部分。在可与本文中描述的其他实施方式组合的一个实施方式中,图像传感器组件204包括一个或多个图像传感器系统212中的每一个,图像传感器系统212位于面向物体101的一个或多个表面103的固定位置。因此,无需旋转物体101就可确定z轴位置并采集3D图像。在可与本文中描述的其他实施方式组合的其他实施方式中,由平台210旋转物体101和/或使一个或多个图像传感器系统212围绕平台210的圆周231移动。
[0030]图5是用于确定3D物体的涂层厚度的方法500的流程图。在可与本文中描述的其他实施方式组合的一个实施方式中,测量装置102用于方法500。在操作501处,执行子方法300和子方法400中的一个以采集一个或多个3D图像。在可与本文中描述的其他实施方式组合的一个实施方式中,执行子方法300和子方法400中的一个以采集物体101的未涂覆表面的至少一个第一3D图像和物体101的涂覆表面的至少一个第二3D图像。在所述实施方式中,未涂覆表面和涂覆表面对应于物体101的一个或多个表面103的相同表面。在可与本文中描述的其他实施方式组合的另一个实施方式中,子方法400采集具有未涂覆部分和涂覆部分的表面的至少一个第一3D图像。第一3D图像包括第一3D图像的表面在z轴207上的z轴位置(z1、z2、......、zn)。第二3D图像包括第二3D图像的表面在z轴207上的z轴位置(z1、z2、......、zn)。
[0031]在可选的操作502处,对一个或多个3D图像在z轴207上进行镜像处理。经镜像处理的一个或多个3D图像与表面轮廓相对应。在可与本文中描述的其他实施方式组合的一个实施方式中,对第一3D图像在z轴207上进行镜像处理,使得经镜像处理的3D图像与未涂覆表面的第一表面轮廓相对应。在可与本文中描述的其他实施方式组合的另一个实施方式中,对第一3D图像在z轴207上进行镜像处理,使得经镜像处理的第一3D图像与表面的未涂覆部分的第一表面轮廓和涂覆部分的第二表面轮廓相对应。经镜像处理的第二3D图像与涂层表面的第二表面轮廓相对应。在操作503处,移除一个或多个3D图像的异常值。在可与本文中描述的其他实施方式组合的一个实施方式中,移除第一3D图像和第二3D图像的异常值。在可选的操作504处,选择一个或多个3D图像的区域以用于操作505至507。在可与本文中描述的其他实施方式组合的一个实施方式中,选择第一3D图像和第二3D图像以用于操作505至507。在操作505处,对一个或多个3D图像进行滤波。在可与本文中描述的其他实施方式组合的一个实施方式中,对第一3D图像和第二3D图像进行滤波。在可与本文中描述的其他实施方式组合的一个实施方式中,利用高斯滤波器对第一3D图像和第二3D图像进行滤波。对第一3D图像和第二3D图像进行滤波可移除图像噪声和表面粗糙度中的一个。
[0032]在可选的操作506处,重叠一个或多个3D图像。在可与本文中描述的其他实施方式组合的一个实施方式中,第一3D图像和第二3D图像被重叠。当第一3D图像包括未涂覆部分和涂覆部分时,由于未采集第二3D图像,因此不必重叠第一3D图像和第二3D图像。在操作507处,减去一个或多个图像的表面轮廓。在可与本文中描述的其他实施方式组合的一个实施方式中,从第一表面轮廓减去第二表面轮廓以获得涂层的厚度。在可选的操作508处,重复操作502至507。在可与本文中描述的其他实施方式组合的一个实施方式中,对通过子方法300和子方法400中的一者所采集的至少一个后续第一3D图像和至少一个后续第二3D图像重复操作502至507。在可与本文中描述的其他实施方式组合的另一个实施方式中,重复操作501至508以采集附加表面的一个或多个3D图像并对其进行分析。
[0033]综上,提供了一种用于确定三维(3D)物体的涂层厚度的非破坏性测量装置和非破坏性测量方法。在图像传感器系统的飞行时间配置和结构光配置之外进一步利用非破坏性图像采集方法允许在不化学地或物理地改变物体的一个或多个表面的情况下确定3D物体的涂层厚度。
[0034]尽管前述内容针对的是本公开内容的示例,但在不脱离本公开内容的基本范围的情况下,可设想本公开内容的其他和进一步示例,并且本公开内容的范围由所附权利要求书确定。