Abstract:
A method for determining the range of a dimensional parameter of a multiplicity of members is provided. The method includes the steps of: providing at least two sensors; fixing a set constant distances (Δl) between the sensors such that the relative distances between sensors are fixed and free from adjustment; and measuring the dimensional parameter based upon a ratio (Δt 2 /Δt 1 ) of a first time segment (Δt 1 ) and a second time segment (Δt 2 ), whereby no adjustment of the relative distance between sensors is required.

Description:
FIELD OF THE INVENTION  
       [0001]     The invention pertains to the field of measurement of the length of a part. More particularly, the invention pertains to part measurement technique using two or more proximity sensors.  
       BACKGROUND OF THE INVENTION  
       [0002]     It is known to use a single sensor for measuring the length of a part. U.S. Pat. No. 5,430,665 teaches an apparatus and method for measuring length of moving elongated object.  
         [0003]     Further, it is also known to use multiple sensors, wherein at least one sensor needs to be adjusted in relation to the other sensors for measuring a part having a specific length. For example, it is known to use multiple sensors in a line to measure length, in which system relies on precise positioning to measure length.  
         [0004]     However, for the above types of known measurements, the sampling rates of even the fastest of these systems was not adequate to dynamically measure the length of a moving pin. For accurate measurements the pins had to be held static momentarily. Since the minimum rates were determined to be 10 or more parts per second, the concept of static sampling is not practical. Because no cost effective off-the-shelf sensor or sensor systems were capable of measuring pin length within the tolerances required and at the rates required, therefore a new measuring method or system is needed.  
       SUMMARY OF THE INVENTION  
       [0005]     A method for determining the length of a multiplicity of individual parts using at least 2 sensors where the relative distance between the 2 sensors is fixed in that the relative distance is not adjusted during the determining step.  
         [0006]     A method for determining the range of a dimensional parameter of a multiplicity of members is provided. The method includes the steps of: providing at least two sensors; fixing a set constant distances (Δl) between the sensors such that the relative distances between sensors are fixed and free from adjustment; and measuring the dimensional parameter based upon a ratio (Δt 2 /Δt 1 ) of a first time segment (Δt 1 ) and a second time segment (Δt 2 ), whereby no adjustment of the relative distance between sensors is required.  
         [0007]     A method for determining the range of a dimensional parameter of a multiplicity of members is provided. The method includes the steps of: providing at least two sensors including a first sensor and a second sensor; fixing a set of constant distances (Δl) between the sensors including at least one distance between the first sensor and the second sensor, such that the relative distances between sensors are fixed and free from adjustment during the sensors&#39; sensing operation; and measuring the dimensional parameter based upon a ratio (Δt 2 /Δt 1 ) of a first time segment (Δt 1 ) and a second time segment (Δt 2 ), whereby no adjustment of the relative distance between sensors is required.  
         [0008]     A method for determining the range of a dimensional parameter of a multiplicity of members is provided. The method includes: providing two sensors, including a first sensor and a second sensor; fixing a constant distance (Δl) between the a first sensor and a second sensor such that the relative distances between sensors are fixed and free from adjustment; moving the multiplicity of members relative to the two sensors; predetermining a point on each member; recording a first time segment (Δt 1 ); recording a second time segment (Δt 2 ); and computing a dimension of the member. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0009]      FIG. 1  shows a part measurement system of the present invention.  
         [0010]      FIG. 2  shows a set of measured signals for proposed two sensor or proximity switch length measurement technique of the present invention.  
         [0011]      FIG. 3  shows an alternative embodiment of the present invention.  
         [0012]      FIG. 3   b  shows the signals available from the  3  sensor technique.  
         [0013]      FIG. 4  shows a diagrammatic depiction of a pin length selection system.  
         [0014]      FIG. 5  shows the prototype installation on a V-track that is automatically fed from a vibrating bowl feeder.  
         [0015]      FIG. 6  shows sorting program in operation. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]     This section includes the descriptions of the present invention including the preferred embodiment of the present invention for the understanding of the same. It is noted that the embodiments are merely describing the invention. The claims section of the present invention defines the boundaries of the property right conferred by law.  
         [0017]     Referring to  FIG. 1 , a part measurement system  10  is shown. The purpose of the system is to quickly or efficiently measure a multiplicity of parts which comprises desired parts as well as undesirable parts. As shown, a multiplicity of parts  12  and some undesired foreign parts  14  are provided for measurement. The parts  12  and undesired foreign parts may be movably traveling through a channel  16  which form a physically constricting means for channeling parts  12  and parts  14  for desired measurement. Note that channel  16  may not be needed in that parts  12  and parts  14  may be free falling from one area to another area and during the free falling period be measured by system  10 . Foreign parts  14  are parts inadvertently or undesirably got mixed together with parts  12 . This mixing together may include production error of parts. As can be seen, the variations of parts  12  and parts  14  can be very small in the context of the total dimension of parts  12  and parts  14  respectively.  
         [0018]     Foreign parts  14  are parts which need to be first identified and preferably later taken out according to the teachings of the present invention. A plurality of sensors including first sensor  18  and second sensor  20  are stably positioned in relation to the parts including multiplicity of parts  12  and some undesired foreign parts  14 , which move in relation to the sensors, i.e. first sensor  18  and second sensor  20 . A controller  22  is coupled to the sensors for processing the sensed information. By stably positioned, it means that the distance  28  between first sensor  18  and second sensor  20  is a constant at least during the parts measurement process or period. In other words, distance  28  may be adjustable, but during the parts measurement distance  28  is fixed or is a constant. This adjustability is desirable in that for a measurement of a different part dimension, it is preferable to adjust or change distance  28  to correspond to the different part dimension. By way of an example, if a pin length is the thing subject to measurement, distance  28  can be adjusted to be substantially identical to the pin length in order to have a more efficient measurement. However, it needs to be made clear that a key provision of this technique is that the distance  28  is not critical to the function of the system. That is what makes the technique of the present invention different from other methods like the one described in the Background section of the present invention. It needs to be stressed that in the description supra, the positioning of the sensors need only be approximate for this technique to work. In other words, absolute accurate positioning of the distance between the sensors are not required. Of course, proper positioning can increase the accuracy and repeatability but that is only required for very special situations. In its basic form this technique is independent of the sensor location relative to each other.  
         [0019]     This is especially true when the multiplicities of pins are moving at high speed. For detailed discussion, see infra.  
         [0020]     A set of receivers may be provided for receiving the sensor signals coming from the sensors. Note that only two sensors i.e. sensor  18  and sensor  20 , with their respective receivers, i.e. receiver  18   a  and receiver  20   a  are shown. The set of receivers and their sensors are each coupled to the microcontroller  22  respectively. Note that receivers such as receiver  18   a  and receiver  20   a  may not be needed in the present invention. For example, when the sensors are reflective sensors, receivers may not be needed.  
         [0021]     It is noted that the distance between the parts (i.e. gap  26 ) is irrelevant to the function of the technique of the present invention. It is the presence, not the absence of parts as a single part passes the sensors that are being sensed.  
         [0022]     In most sensor systems, the sensor therein may be directed to sense at only a predetermined direction. In other words, all the sensors involved do not need to be focused upon point  24 . For example, as indicated by the dotted line  18   b  and  20   b  described supra respectively, a non-focused system is depicted. It is noted that by “focused”, it is meant that the sensors have their respective sensing points as one identical point. In other words, by “focused”, it is meant that the sensors sensing directions are focused at a single point. For example, at the instant as shown in  FIG. 1 , sensor  18  has its sensing rays  18   b  blocked by pin  12  such that receiver  18   a  cannot received communication coming from sensor  18 . At this juncture, a different signal (or first signal) is fed to microprocessor  22 . when a sensor can communicate with its receiver such as shown in the figure with regard to sensor  20  in which sensing rays  20   b  is received by receiver  18   a  due to the crevice or the junction  26  between pins (in this example, between two pin  12 ), a second signal is fed to microprocessor  22 . As such, system  10  is disposed to know information relating to the length of pin  12  or pin  14 , and thereby processing the same according to the teachings of the present invention. One way to process the information is to record the time periods that have elapsed with regard to the sensors, be they first sensor  18 , second sensor  20  or third or fourth sensors (not shown) if required.  
         [0023]     Alternatively, sensor  20  may have a built in receiver (not shown) which performs similar functions as receiver  20   a  in feeding information back to microcontroller  22 . Sensor  18  may constitute substantially identical receiver therein for similar purposes.  
         [0024]     Furthermore, the positioning between the sensors is fixed and independent of the part length. In other words, any distance between any two points with one point on one sensor and the other point on the other sensor is a constant. There exists a fixed distance  28  between sensor  18  and sensor  20 . Distance  28  is a constant. The present invention contemplates a set of sensors for sensing parts  12 ,  14  in which the sensors are positioned such that no relative movement of any sensor is required.  
         [0025]     Referring to  FIG. 2 , a method of processing the information sensed according to  FIG. 1  is shown. More specifically, a set of measured signals for proposed two proximity switch length measurement technique is shown. Δl is defined as the distance between the sensors switches, such as distance  28  of  FIG. 1 . Further, Δl is a known value in that it is fixed at least during measurement. Therefore, we can calculate the pin velocity: 
 
 V   pin   =Δl/Δt   1  
 
 wherein Δt 1  is the time segment from a point in which the length of a part (such as a pin) entering a first sensor range until the point is sensed by a second sensor. As can be seen, since Δl is a known value, V pin  is dependent upon the variations of Δt 1 . 
 
         [0026]     Using this velocity we arrive at or can calculate the pin length, l pin  as:  
         l   pin     =         V   pin     ×   Δ   ⁢           ⁢     t   2       =     Δ   ⁢           ⁢     l   ⁡     (       Δ   ⁢           ⁢     t   2         Δ   ⁢           ⁢     t   1         )               
 
 wherein Δt 2  is the time segment required for the length of a part (such as a pin) to pass a single sensor, be it the first sensor  18  , the second sensor  20 , or other extra sensors. 
 
         [0027]     It is noted that velocity of the moving parts such as the pins may not be a constant. In other words, the velocity may a variable or function that change with the passing of time. If this is the case, some adjustments are required. The adjustment includes changing the ratio (Δt 2 /Δt 1 ). It is noted that high velocity is an important feature taking into consideration by the present invention. A working definition of “high” velocity is that the speed at which the parts subject to measurement pass a sensor (or sensors) so fast that effective measurements using known means are in sufficient. For example, a “low” velocity, one may merely use a single sensor for measurement. The sensor may even be the naked eye of humans.  
         [0028]     Since the value of Δ/is fixed, the measured pin length is proportional to the ratio (Δt 2 /Δt 1 ).  
         [0029]     Referring to  FIG. 3 , an alternative embodiment  10   a  of the present invention is shown. In addition to the elements shown in  FIG. 1 , a third sensor  21  is added, which in turn has sensing ray  21   b  directed at pins for sensing variations thereto. A receiver  21   a  may be provided for receiving ray  21   a  from sensor  21 . Alternatively, sensor  21  may have a built in receiver (not shown) which performs similar functions as receiver  21   a  in feeding information back to microcontroller  22 .  
         [0030]     Additionally, a third sensor  21  is provided. Sensor  21  may sense parts via a focused sense line  21   a  that being focused upon a single point on the moving parts  12 ,  14 . As can be appreciated, the single point  24  is also the point being focused by sensor  18  and sensor  20 . Alternatively, sensor  21  may have a non-focused sensing line  21   b.    
         [0031]     During measurement, sensor  21  has a fixed position thereby its relative distance to sensor  18  and sensor  20  is a pair of constants respectively. In other words, distance  28   a  or distance  28   b  is respectively of a fixed value or constants. It is noted that in a three dimensional condition, the sensors may not be mounted along a straight line. That is to say, the value of distance  28   b  may not be the sum total of the values of distance  28  and distance  28   a.    
         [0032]     As can be seen, for three or more sensor systems such as system  10   a,  the relationships between information sensed by each sensor are more elaborate. In other words, each sensor has its own Δt 2  and Δt 1 . For any one of the more than three sensor, instead of only one other sensor for correlation purpose, more than one sensor is involved. As can be seen, this allows for multiple and alternate calculations of the ratio (Δt 2 /Δt 1 ) and can produce a more robust approach to length sensing. This is especially true when the parts are changing velocity over the sensor separation length ( 28 ,  28   b ).  
         [0033]     For example, in  FIG. 3   b  which shows the signals available from the  3  sensor technique and the additional available (Δt) values are available for alternate calculations.  
         [0034]     It is noted that in the ideal condition, two sensors are theoretically sufficient for the present invention. The distance between the two sensors is preferably set to equal the parts length subject to measurement. However, due to the fixed distance nature of the present invention, parts length subject to measurement cannot always be the same. Further factors involved are the error in measurement inherent in any sensor, the velocity of the movement of the parts subject to measurement, and the length or dimensional difference between the desired parts and the undesired parts, etc. Therefore, more than two sensors may be introduced thereby more parameters can be measured and thereby provided more row data for a improved accuracy in the measurement of the present invention.  
         [0035]     Referring to  FIG. 4 , a diagrammatic depiction of a pin length selection system is shown. Parts to be tested pass through channel  16 . Note that the parts can be desired parts  12  as well as undesired parts  14 . The parts, while in channel  16 , are sensed by sensor unit  30 , which may include first sensor  18 , and second sensor  20 , or other sensors (not shown). Actuators such as first actuator  32  and second actuator  34  are provided for selectively collecting desired parts  12  in a pass container and parts  14  in a fail container. First actuator  32  and second actuator  34  each respectively receives command from microprocessor  22  and is informationally coupled thereto. The following is an example that evaluates several variations on this concept of the present invention. The hardware involved includes  
         [0036]      FIG. 5  shows the prototype installation on a V-track that is automatically fed from a vibrating bowl feeder. A microcomputer was programmed to interpret the sensor output and calculate the (Δt 2 /Δt 1 ) ratio.  
         [0037]      FIG. 6  shows sorting program in operation. At this time testing is ongoing on this technique but initial results indicate that the method is quite accurate with proper sensor orientation and setup. As discussed supra, the fact that sensor positioning is not critical to the basic function of this system of course better results can be achieved by modifying the sensor position but it is also found that at high speed, repeatable sensors are better and that proper part presentation can also improve the accuracy and repeatability. By way of an example, repeatability of ±0.0005″ has been demonstrated for pin speeds up to 35 inches per second. Additional testing will consider throughput capabilities and long term durability of the system for offline pin sorting in the production environment. Note the graphic window therein for easy user determination.  
         [0038]     The present invention contemplates that any number of members having a physical dimension can be measured using the method described supra. Of course a means need be provided to move the members relative to at least two sensors.  
         [0039]     Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. References herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.