Abstract:
An inspection system and a method for using the inspection system, wherein the inspection system includes a collimated light source defining a source optical path, the collimated light source being operable to cause a collimated light beam to propagate along the source optical path, a sensing device defining a sensor optical path, the sensor optical path being substantially perpendicular to the source optical path, a reflecting device disposed within the source optical path to receive the collimated light beam, the reflecting device causing a reflected collimated light beam to propagate along the sensor optical path to the sensing device and a retention mount, the retention mount being disposed within the sensor optical path such that when a component is retained within the retention mount, the component blocks at least a portion of the reflected collimated light beam.

Description:
RELATED APPLICATIONS  
       [0001]    This application claims priority from U.S. Provisional Patent Application No. 60/389,357 filed Jun. 17, 2002, the contents of which are hereby incorporated by reference herein. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This disclosure relates generally to a method and system for inspecting components and more particularly to a method and system for optically inspecting the physical characteristics of externally threaded components, such as thread gages, screws, bolts and other externally threaded components having varied configurations.  
         BACKGROUND OF THE INVENTION  
         [0003]    As society becomes increasingly reliant upon technology, mechanical and electromechanical systems, such as aircraft, automobiles, weapons systems and power systems, are called upon to perform an ever increasing number of functions. One downside to this is that, in some situations, a failure of a single threaded component in the system may cause a catastrophic failure of the entire system possibly resulting in the loss of millions of dollars and hundreds of lives. In an attempt to reduce the probability of a catastrophic systems failure, critical and some non-critical systems are required to satisfy predetermine operating tolerances before they may be used. As such, key threaded components within these systems, i.e. threaded components whose failure may cause a catastrophic system failure such as screws and/or gages, must also satisfy operating tolerances. If a threaded component fails to satisfy these required design tolerances and/or performance specifications, a degradation of system performance and/or a total system failure may occur resulting in damage to the system and/or injury/loss of life to an operator.  
           [0004]    One of the current systems used for inspecting the physical characteristics of a threaded component employ an attribute inspection approach that measures the characteristics of the threaded component via a contact measurement technique which does not protect product design limits. This technique uses GO and/or No Go ring gages that are adjusted, or calibrated, to a desired thread measurement via Go and/or No Go setting plugs. Unfortunately, this technique does not ensure the integrity of design limits and because this approach is dependent upon human interaction, this technique has the disadvantage of being time consuming, subjectively inaccurate and unreliably repeatable for tight operating tolerances, thus permitting threaded components having dimensionally non-conforming characteristics to pass inspections. Moreover, there is a considerable wear factor on the measuring instruments, requiring the Go, No Go setting plugs to be inspected and replaced often.  
           [0005]    Another approach used for measuring external thread gages utilizes three wires communicated to the gage being measured. The three wires are of a known diameter and are typically disposed between the threads of a component such that the wires protrude from the threads, wherein two wires are disposed on one side of the threaded component and one wire is disposed on the opposing side of the threaded component. The diameter over the wires is then measured via a human inspector. Because the wires are of a known diameter, this allows certain characteristics of the threads to be determined by measuring the width of the wires disposed between the threads. Unfortunately, this approach is also dependent upon human interaction. If the inspector measuring the distance over the wires compresses the wires too much, the wires may become deformed resulting in an inaccurate measurement. Additionally, the surface finish of a threaded component may adversely affect the accuracies of these measurements. Moreover, because the wires are loose and are not held between the threads, the wires may be dropped which may result in the wires becoming contaminated with dirt, the wires being lost or, if someone steps on them, the wires being deformed. Furthermore, different operators will generate different gage pressures on the wires which may cause erroneous readings. Thus, this approach has the similar disadvantage of being time consuming, subjectively inaccurate and unreliably repeatable for tight operating tolerances, thus also permitting threaded components having dimensionally non-conforming characteristics to pass inspections. Additionally, the reliability and repeatability of this measurement is very poor because an operator must measure angles using an optical projection which is also time consuming, inaccurate and often fails to satisfy current product and gage calibration specifications. As such, the Measurement Uncertainty Factor (MUF) in many situations exceeds the required tolerances and as a result, the required accuracies for complete certification of these methods have thus far been unobtainable.  
           [0006]    Therefore, it would be desirable to provide a measurement device that is capable of accurately, consistently, reliably and quickly measuring the physical characteristics of a threaded component without human interaction.  
         SUMMARY OF THE INVENTION  
         [0007]    The present disclosure addresses the above-identified need by providing an inspection system having a collimated light source defining a source optical path, the collimated light source being operable to cause a collimated light beam to propagate along the source optical path, a sensing device defining a sensor optical path, the sensor optical path being substantially perpendicular to the source optical path, a positioning device including a positioning device stage, the positioning device stage movably disposed relative to the sensing device and the collimated light source, a reflecting device, the reflecting device disposed on the positioning device to be within the source optical path to receive the collimated light beam, the reflecting device causing a reflected collimated light beam to propagate along the sensor optical path to the sensing device and a retention mount, the retention mount being disposed within the sensor optical path such that when a component is retained within the retention mount, the component blocks at least a portion of the reflected collimated light beam.  
           [0008]    Also provided is a method for measuring physical characteristics of a threaded component using an inspection system comprising: obtaining an inspection system and a component to be measured, wherein the inspection system includes a light source, a sensing device, a reflecting device, and a retention mount; associating the component with the inspection system such that the component is disposed within the retention mount; operating the inspection system to cause the light source to emit a collimated light beam propagating along a source optical path; reflecting the collimated light beam via the reflecting device to cause a reflected collimated light beam to propagate along a sensor optical path such that the reflected collimated light beam is incident upon the component to produce a component silhouette which is incident upon the sensing device; generating image data responsive to the component silhouette; and processing the image data to generate resultant data comprising at least one of a plurality of physical characteristics of the component.  
           [0009]    A medium encoded with a machine-readable computer program code, the program code including instructions for causing a controller to implement a method for measuring physical characteristics of a component using an inspection system, comprising: obtaining a component to be measured, wherein the inspection system includes a light source, a sensing device, a reflecting device, and a retention mount; associating the component with the inspection system such that the component is disposed within the retention mount; operating the inspection system to cause the light source to emit a collimated light beam propagating along a source optical path; reflecting the collimated light beam via the reflecting device to cause a reflected collimated light beam to propagate along a sensor optical path such that the reflected collimated light beam is incident upon the component to produce a component silhouette which is incident upon the sensing device; generating image data responsive to the component silhouette; and processing the image data to generate resultant data comprising at least one of a plurality of physical characteristics of the component.  
           [0010]    A machine-readable computer program code, the program code including instructions for causing a controller to implement a method for measuring physical characteristics of a component using an inspection system, comprising: obtaining a component to be measured, wherein the inspection system includes a light source, a sensing device, a reflecting device, and a retention mount; associating the component with the inspection system such that the component is disposed within the retention mount; operating the inspection system to cause the light source to emit a collimated light beam propagating along a source optical path; reflecting the collimated light beam via the reflecting device to cause a reflected collimated light beam to propagate along a sensor optical path such that the reflected collimated light beam is incident upon the component to produce a component silhouette which is incident upon the sensing device; generating image data responsive to the component silhouette; and processing the image data to generate resultant data comprising at least one of a plurality of physical characteristics of the component.  
           [0011]    The above discussed and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0012]    Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:  
         [0013]    [0013]FIG. 1 shows a perspective side view of a component inspection system;  
         [0014]    [0014]FIG. 2 shows a side view of a component inspection system;  
         [0015]    [0015]FIG. 3 shows a close up side view of a component inspection system;  
         [0016]    [0016]FIG. 4 shows a front view of a component inspection system;  
         [0017]    [0017]FIG. 5 shows a close up perspective front view of a component inspection system;  
         [0018]    [0018]FIG. 6 shows a close up front offset view of a component inspection system having a component disposed between arbors;  
         [0019]    [0019]FIG. 7 shows a schematic block diagram of a collimated light source;  
         [0020]    [0020]FIG. 8 shows a front view of a component disposed between arbors of a component inspection system;  
         [0021]    [0021]FIG. 9 shows a schematic block diagram of a component inspection system;  
         [0022]    [0022]FIG. 10 shows a side view of a threaded component;  
         [0023]    [0023]FIG. 11 show a side view of a threaded component;  
         [0024]    [0024]FIG. 12 shows a block diagram illustrating an overall method for measuring the characteristics of a component using a component inspection system;  
         [0025]    [0025]FIG. 13 shows a block diagram illustrating a component/gage selection algorithm;  
         [0026]    [0026]FIG. 14 shows a GUI screen capture of a component/gage selection screen;  
         [0027]    [0027]FIG. 15 shows a GUI screen capture of a component/gage selection screen;  
         [0028]    [0028]FIG. 16 shows a GUI screen capture of a component/gage selection screen;  
         [0029]    [0029]FIG. 17 shows a GUI screen capture of a component/gage selection screen;  
         [0030]    [0030]FIG. 18 shows a GUI screen capture of a component/gage selection screen;  
         [0031]    [0031]FIG. 19 shows a block diagram illustrating a calibration algorithm;  
         [0032]    [0032]FIG. 20 shows a reference arbor knee and a search box;  
         [0033]    [0033]FIG. 21 shows a display device illustrating lens distortion measurements;  
         [0034]    [0034]FIG. 22 shows a block diagram illustrating a component measurement algorithm; and  
         [0035]    [0035]FIG. 23 shows a block diagram illustrating an R&amp;R algorithm. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    An exemplary embodiment is described herein by way of illustration as may be applied to the measurement and inspection of threaded gages and product, such as screws, bolts and other externally threaded components. However, while an exemplary embodiment is shown and described hereinbelow, it will be appreciated by those skilled in the art that the invention is not limited to the embodiment(s) and application(s) as described herein, but also to any component and/or measurement where accuracy in tolerance measurement is critical, such as taps, splines, gears, internal bores, integral plane cylindrical bores, internal threads, internal/external diameters and/or material composition and/or strength. Moreover, those skilled in the art will appreciate that a variety of potential implementations and configurations are possible within the scope of the disclosed embodiments.  
         [0037]    Referring to FIGS.  1 - 8 , an inspection system  100  is shown and described. In accordance with an exemplary embodiment, inspection system  100  includes a collimated light source  102 , a sensing device  104 , a reflecting device  106 , a component support device  108  and a system support structure  110 . System support structure  110  includes a base support structure  112 , a base structure  114 , a bridge structure  116  defining a bridge cavity  118 , a light source mounting device  120  and a sensor mounting device  122 . Base support structure  112  is disposed to be supportingly associated with base structure  114  and base structure  114  is disposed to be supportingly associated with bridge structure  116 , wherein bridge cavity  118  is disposed between bridge structure  116  and base structure  114 .  
         [0038]    Collimated light source  102  is preferably associated with base structure  114  via light source mounting device  120  such that light emitted from collimated light source  102  propagates along a source optical path which is defined by collimated light source  102  and which is parallel to base structure  114 . Sensing device  104  is preferably associated with bridge structure  116  via sensor mounting device  122 , wherein sensing device  104  defines a sensor optical path which perpendicularly intersects the source optical path. Although, base structure  114  and bridge structure  116  are preferably constructed from a non-metallic polymer casting, it is contemplated that base structure  114  and bridge structure  116  may be constructed from any shock, vibration and/or movement attenuating material(s) and/or composite(s) suitable to the desired end purpose.  
         [0039]    Component support device  108  includes a positioning device  124  and a mounting base  126 , wherein mounting base  126  is associated with base structure  114 . Positioning device  126  includes a positioning stage  128  and a component retainer  130 , wherein component retainer  130  is associated with positioning stage  128  and includes a first arbor  132  separated from a second arbor  134  via an arbor cavity  136  and wherein at least one of first arbor  132  and/or second arbor  134  includes a notched potion, or arbor reference “knee” position  220 . Positioning stage  128  is preferably positionally and controllably configurable in all planes (such as x-plane, y-plane, z-plane) relative to mounting base  126  via a motor operated by a motor controller. At least one of first arbor  132  and second arbor  134  are configurable for retaining a component within component retainer  130 . Reflecting device  106  is preferably associated with positioning stage  128  such that reflecting device  106  is disposed at an angle of 45° relative to the surface of positioning stage  128  and such that reflecting device  106  is disposed in the same plane as first arbor  132 , second arbor  134  and arbor cavity  136  (i.e. sensor optical path). Additionally, component support device  108  is preferably disposed within bridge cavity  118  such that reflecting device  106  is disposed at the intersection of the source optical path and the sensor optical path. Although reflecting device  106  is preferably a high quality 0.25 wave length first surface style mirror, reflecting device  106  may be any high quality reflective surface device suitable to the desired end purpose.  
         [0040]    Sensing device  104  includes a high resolution camera  137  having a microscope-type telecentric optical lens  138  and although sensing device  104  is preferably powered via an external power source, sensing device  104  may be powered using any power source suitable to the desired end purpose, such as a battery. Moreover, although microscope type tele-centric optical lens  138  preferably has a magnification factor of 2.6×, microscope type tele-centric optical lens  138  may have any magnification factor suitable to the desired end purpose. Furthermore, although sensing device  104  is a VISICS CCD camera having a microscope type telecentric optical lens system with 2.6× magnification, it is contemplated that sensing device  104  may be any sensing device suitable to the desired end purpose.  
         [0041]    Referring to FIG. 7, collimated light source  102  includes a Light Emitting Diode (LED)  140 , a collimating lens  142  and a lens cap  144  having a lens slot  146  disposed to minimize the stray emission of light emitted from collimating lens  142 . In addition, collimated light source  102  is preferably associated with base structure  114  such that collimating lens  142  is in optical line of sight with reflecting device  106 . Moreover, although collimated light source  102  is preferably powered via an external power source, collimated light source  102  may be powered using any power source suitable to the desired end purpose, such as a battery.  
         [0042]    Inspection system  100  is constructed such that when LED  140  is energized a beam of light is emitted from LED  140  and is projected such that the beam of light becomes incident upon collimating lens  142 . Collimating lens  142  collimates the beam of light to create a collimated light beam  148 , which is then emitted from collimating lens  142 . Upon exiting collimating lens  142 , collimated light beam  148  propagates along the source optical path and becomes incident upon reflecting device  106 , which is disposed at an angle of 45° relative to the surface of positioning stage  128 . Reflecting device  106  then reflects incident collimated light beam  148  and the reflected collimated light beam  150  propagates along the sensor optical path to become incident upon sensing device  104 . However, because reflecting device  106  is disposed in the same plane as first arbor  132 , second arbor  134  and arbor cavity  136  (i.e. sensor optical path), before reflected collimated light beam  150  becomes incident upon sensing device  104 , reflected collimated light beam  150  becomes incident upon first arbor  132 , second arbor  134  and arbor cavity  136 . As such, when a component is disposed within component retainer  130  to be between first arbor  132  and second arbor  134 , reflected collimated light beam  150  becomes partially blocked by the component, first arbor  132  and/or second arbor  134  and as a result, a shadow or silhouette of the component, first arbor  132  and/or second arbor  134  is created and communicated to sensing device  104 .  
         [0043]    Referring to FIG. 9, an overall block diagram of inspection system  100  is shown and described. Inspection system  100  is shown as including a processing device  152  having a display device  154 , camera controller circuitry  156  and a communications port  158 , wherein processing device  152  is disposed to be in communication with collimated light source  102 , sensing device  104  and positioning device  124 . In accordance with an exemplary embodiment, collimated light source  102  is shown in optical communication with reflecting device  106  such that collimated light beam  148  emitted from collimated light source  102  is incident upon reflecting device  106 . Reflecting device  106  reflects collimated light beam  148  to produce reflected collimated light beam  150 . Sensing device  104  is shown in optical communication with reflecting device  106  such that reflected collimated light beam  150  is incident upon sensing device  104  to be received by high resolution camera  137  via microscope type tele-centric optical lens  138 . Thus, when a component is disposed between first arbor  132  and second arbor  134 , the silhouette of the component, first arbor  132  and/or second arbor  134  is also received by high resolution camera  137 .  
         [0044]    High resolution camera  137  converts the silhouette image into image data and communicates this image data to processing device  152 , wherein the image data is responsive to the interaction between the component and reflected collimated light beam  148  received by telecentric optical lens  138 . Processing device  152  then examines this image data to determine if more image data is required. If more image data is required, processing device  152  instructs sensing device  104  to obtain more image data. If necessary, processing device  152  may control the position of positioning device  126  via communications port  158  to dispose positioning device  126  as necessary in a manner responsive to the desired image data. Although processing device  152  is preferably communicated with positioning device  126  via an RS-232 or RS-422 communications port, processing device  152  may be communicated with positioning device  126  via any device and/or method suitable to the desired end purpose, such as via wireless communications. Moreover, camera controller circuitry  156  may be communicated with processing device  152  via any method and/or device suitable to the desired end purpose. Furthermore, although high resolution camera  137  is preferably an electronic camera being able to support an image size of up to at least 1296×1016 pixels, high resolution camera  137  may be any high resolution camera  137  suitable to the desired end purpose.  
         [0045]    It is further contemplated that, although display device  150  is preferably a flat panel display device having a 1280×1024 display capability, display device  150  may be any display device and/or method suitable to the desired end purpose. Additionally, although processing device  152  is preferably a computer system operating an MS Windows 2000 operating system (or higher version) and having a Pentium processor with at least 128 Mb RAM, Ethernet network capability and a wireless communications device, such as a modem, DSL or Ti line, processing device  148  may be any processing device suitable to the desired end purpose. Positioning device  126  preferably includes a cast iron stage with a glass slide and a linear motor having crossed rollers with patented anti-creep technology. The linear motor preferably allows for at least plus and minus three (3) inches of travel in both X and Y axes and allows for a maximum load of at least 635 Kg. Positioning device  126  also preferably includes a digital motor (servo) controller having an integral drive with a digital current loop and is communicated with processing device  152  via an RS-232/RS-422 communications port. Additionally, the digital motor (servo) controller is preferably capable of supporting a 10-30 amp peak, 6-15 amps continuous and a 170-300 VDC bus and although the digital motor (servo) controller is preferably capable of supporting movement in the X and Y axis, it is contemplated that digital motor (servo) controller may also be capable of supporting movement in the Z axis, as well.  
         [0046]    Operation of System  
         [0047]    Referring to FIG. 10 and FIG. 11, a side view of an externally threaded component, such as a threaded product is shown and discussed. A component thread is a combination of a thread ridge and groove, typically of uniform section, that is produced by forming a groove with a helix on an external or internal surface of a cylinder or cone. Because the component thread is designed to operate in association with an opposing component thread, it is essential that certain key physical characteristics relating to thread size and thread form be tightly controlled. As such, it is desirable to measure these thread size characteristics and thread form characteristics as accurately as possible. The thread size characteristics include the major diameter, the minor diameter, the functional diameter and the pitch diameter and the thread form characteristics include the pitch, the lead, the uniformity of helix angle, the flank angle and the included angle, each one of which is discussed in more detail hereinbelow.  
         [0048]    The Major Diameter  
         [0049]    The major diameter of the component is the diameter or width of an imaginary cylinder, called the major cylinder, whose surface would be parallel to the straight axis of the component and whose surface would bound the crests of an external thread or the roots of an internal thread. However, although both threaded gages and threaded products typically have a full form major diameter, threaded gages also typically have a truncated major diameter. As such, a threaded gage includes a full form major diameter and a truncated major diameter and a threaded product only includes a full form major diameter. The full form major diameter, for both a threaded gage and a threaded product, may be defined as a composite measurement responsive to the major radius (which may be defined as the distance between the component axis and one surface of the major cylinder or one half of the major diameter) measured on the 0° side of the full form threads and the major radius measured on the 180° side of the full form threads. However, for a threaded gage, the truncated major diameter may be defined as a composite measurement responsive to the major radius measured on the 0° side of the truncated threads and the major radius measured on the 180° side of the truncated threads.  
         [0050]    The Minor Diameter  
         [0051]    The minor diameter of the component is the diameter of an imaginary cylinder, or minor cylinder, whose surface would be parallel to the straight axis of the component and whose surface would bound the roots of an external thread or the crests of an internal thread. Thus, the minor radius, which may be defined as the distance between the component axis and one surface of the minor cylinder or one half of the minor diameter, and which is typically measured using the first thread on the 0° side, is typically determined using a best fit radius that is tangential to the flanks and that has no reversals.  
         [0052]    The Pitch and Pitch Diameter  
         [0053]    The pitch of a thread having uniform spacing may be defined as the distance, measured parallel to the axis, between corresponding points on adjacent thread forms in the same axial plane and on the side of the axis. Thus, the pitch may be defined as the number of threads per inch (TPI) and the pitch distance may be defined as 1/TPI, wherein TPI is measured parallel to the thread axis, from a point on one flank to the corresponding point on the next available flank. The pitch diameter of the component is the diameter or width of an imaginary cylinder, called the pitch cylinder, whose surface would be parallel to the axis of the thread or component and whose surface would intersect the profile of a straight thread such that the width of the thread ridge and the thread groove are equal.  
         [0054]    Thus, the pitch diameter of a threaded gage, which typically includes full form threads and truncated threads, includes a pitch diameter front and a pitch diameter back, wherein the pitch diameter front is responsive to the leading and trailing angles of the thread, the lead and the crest width of the threads at the truncated location and wherein the pitch diameter back is responsive to the leading and trailing angles of the thread, the lead and the crest width of the threads at the full form location. Whereas the pitch diameter of a threaded component, which typically includes only full form threads, includes only a pitch diameter front, wherein the pitch diameter front is responsive to the leading and trailing angles of the thread, the lead and the crest width of the threads.  
         [0055]    The Lead  
         [0056]    The lead may be defined as the axial distance moved by the component in relation to the amount of angular rotation, when a threaded component is rotated about its axis with respect to a fixed mating thread. Thus, the lead is the amount of axial travel when the threaded component is turned one full turn or 360° and pitch is the distance measured parallel to the axis from a point on one flank to the corresponding point on the adjacent flank. Any deviation in lead tends to increase the functional diameter of the external thread (or decrease the functional diameter of the internal thread) and rapidly consumes the allowed operating pitch diameter tolerance of a threaded component. A deviation in lead may result in non-engagement of a screw thread with its mating part at all but a few points. Thus, when the threaded parts are assembled, and torque is applied, the result is pressure being applied to only a few, and possibly only one pressure flank. As such, any deviation in lead may produce a non-engagement condition for some threads and cause a failure in engaging threads at the point of pressure flank engagement due to non-engagement.  
         [0057]    The Uniformity of Helix Angle  
         [0058]    The helical path deviation of a thread is a wavy deviation from a true helical advancement or a non-uniformity of helix angle. In a similar manner as the lead, a deviation in the helical path causes an increase in the functional size of the component in proportion to the amount of waviness. Thus, all of the statements that were made concerning a deviation in lead also apply to a deviation in helical path and similarly, a deviation of helical path may result in partial engagement of the thread flanks with the result that torque pressures may not be evenly distributed and may result in pre-load relaxation.  
         [0059]    The Flank Angle  
         [0060]    The included angle of a thread is the angle between the flanks of the thread measured in an axial plane. The flank angles are the angles between the individual flanks and the perpendicular to the axis of the thread measured in an axial plane. A flank angle of a symmetrical thread is commonly referred to as the half included angle or the half angle of a thread. A deviation in the flank angle may result in a failure of the thread when the product is exposed to line loads or when torque is applied. This is because an improper flank engagement may create an unevenly distributed pressure load along the flank rather than the pressure load being distributed evenly along the flank.  
         [0061]    Other Physical Characteristics  
         [0062]    Other important physical characteristics of the component include the functional size diameter, the taper characteristic of the pitch cylinder and the out-of-roundness, all of which can generate a non-engagement condition. In fact, distortion or deviation from specifications of any of the physical characteristics discussed herein may cause varying degrees of non-engagement.  
         [0063]    The Functional Diameter  
         [0064]    The functional, or virtual, diameter of a thread (external or internal) may be defined as the resultant size of the product thread taking into account the effect of lead, helical path deviation, flank angle deviation, taper and out-of-roundness. As such, it may be seen that the functional diameter is the pitch diameter of the enveloping thread of perfect pitch, lead and flank angles, having full depth of engagement, but that are clear at crests and roots, of specified lengths of engagement. For an external thread, the functional diameter may be derived by adding the cumulative effects of deviations to the pitch diameter (for internal threads subtracting the cumulative effects of deviations), including variations in lead and flank angles over a specified length of engagement. Thus, it should be clear that the effects of taper, out-of-roundness and surface defects may be positive or negative on either external or internal threads, respectively.  
         [0065]    The Taper Characteristic of the Pitch Cylinder  
         [0066]    The taper characteristic of the pitch cylinder is simply a tapering of the pitch cylinder of the thread. As can be seen, a tapered thread fails to give a complete thread engagement, which may lead to a product failure caused by uneven torque pressure conditions on pressure flanks and pre-load relaxation.  
         [0067]    The Out-of-Roundness of the Pitch Cylinder  
         [0068]    The out-of-roundness of the pitch cylinder, which is any deviation of the pitch cylinder from round, limits the thread engagement and allows for only line contact with the mating thread and typically includes two types of out-of-roundness: Multi-lobe or Oval.  
         [0069]    Overall Method of Operation  
         [0070]    With the desired physical characteristics of a threaded component to be measured explained hereinabove, an overall method for measuring these characteristics is provided and described hereinbelow. Furthermore, it is contemplated that each of the methods, calculations and algorithms described herein, may be performed via a system operator and/or via an automated system.  
         [0071]    Referring to FIG. 12, an overall method  300  for measuring the characteristics of a component using inspection system  100  is shown and discussed. In accordance with an exemplary embodiment, inspection system  100  and component  162  is preferably obtained, as shown in block  302 , wherein inspection system  100  includes a light source  102 , a sensing device  104 , a reflecting device  106 , and a component support device  108 . Information regarding the type of threaded component  162  such as a screw, gage, bolt and/or other component, to be measured is determined and communicated to inspection system  100  via system software, as shown in block  304 . Although, this is preferably accomplished via a system operator who enters information regarding threaded component  162  into processing device  152  via a mouse or keyboard in a manner responsive to a component/gage selection algorithm  400 . It is contemplated that component information may be stored in a database and retrieved via sensors, such as bar code readers.  
         [0072]    Once component  162  has been selected and component information communicated to processing device  152  has been completed, component  162  is associated with inspection system  100  to be disposed within component support device  108 , as shown in block  306 . This may be accomplished by a system operator disposing component  162  within component retainer  130  such that component  162  is retained within arbor cavity  136  via first arbor  132  and second arbor  134 . Inspection system  100  is then operated to perform a pre-calibration lens distortion analysis to determine any parabolic lens distortion factors, as shown in block  308 . This pre-calibration lens distortion analysis is a curve fitting routine that is performed prior to the calibration procedure and that is separate from the system lens distortion measurement and correction that is part of the calibration procedure and that is used to compensate for any parabolic distortion that is inherent in optical lens  138 . Although, it will be appreciated that the lens distortion analysis is advantageously provided by the lens manufacturer, it is contemplated that any suitable lens distortion analysis method may be independently developed and/or used.  
         [0073]    In order to perform this analysis, collimated light source  102  emits a collimated light beam that becomes incident upon reflecting device  106 , thus causing a reflected collimated light beam to become incident upon sensing device  104 . Sensing device  104  receives this reflected collimated light beam and generates image data responsive to this reflected collimated light beam. Because the reflected collimated light beam is unimpeded, the image data generated by sensing device  104  is only responsive to the characteristics of collimated light source  102 , reflecting device  106  and sensing device  104 . Thus, the image data may advantageously be examined to determine if lens  138  of sensing device  104  contains any imperfections or distortions. As such, processing device  152  examines the image data to determine whether any variations of image intensity exist within a predefined field of view of lens  138 . This is preferably accomplished by examining portions of the generated image data responsive to a number of various image locations within the field of view of lens  138 , wherein the examined portions are responsive to locations within the vertical and horizontal span of the field of view, ranging from the bottom to the top and from the left hand side to the right hand side of the field of view.  
         [0074]    For example, the image data to be examined preferably includes data points responsive to a plurality of locations on lens  138  that represent the vertical span of lens  138  (or of the field of view of lens  138 ) for both the 0° and 180° side of at least one arbor. The results for each of these data points, which represent the actual vertical distortion characteristics of lens  138 , are then plotted on an actual vertical gradient chart (and compared with an ideal vertical gradient chart provided by the manufacturer of lens  138 , wherein the ideal vertical gradient chart represents the ideal lens characteristics. In a similar fashion, the image data to be examined also preferably includes data points responsive to a plurality of locations on lens  138  that represent the horizontal span of lens  138  (or of the field of view of lens  138 ). As above, the results for each of these data points, which represent the actual horizontal distortion characteristics of lens  138 , are then plotted on an actual horizontal gradient chart and compared with an ideal horizontal gradient chart provided by the manufacturer of lens  138 , wherein the ideal horizontal gradient chart represents ideal lens characteristics. Any deviations between the actual vertical/horizontal gradient charts and the ideal vertical/horizontal gradient charts are recorded and stored for later application in subsequent calculations and/or measurements. It should be noted that, in order to minimize any effect of lens distortion on the measurements, the areas of interest, i.e. areas of component  162  to be measured, are almost always disposed in the center of the field of view for lens  138 .  
         [0075]    Once this has been completed, inspection system  100  is operated to cause positioning stage  128  to be disposed such that the reflected collimated light beam is incident upon component  162 , as shown in block  310 . The reflected collimated light beam incident upon component  162  produces a silhouette of component  162  and/or first arbor  132  which is projected to be incident upon sensing device  104 . Sensing device  104  generates image data responsive to silhouette of component  162  and first arbor  132  and communicates this image data to processing device  152  which processes the image data to generate resultant data, as shown in block  312 . Processing device  152  then instructs inspection system  100  to perform a system calibration in a manner responsive to a predetermined calibration algorithm  500 , as shown in block  314 . Upon completion of predetermined calibration algorithm  500 , inspection system  100  performs a component measurement in a manner responsive to a predetermined component measurement algorithm  600 , predetermined calibration algorithm  500  and/or the results of lens distortion analysis, as shown in block  316 . Once the component measurement has been completed, component information is then displayed to the system operator via display device  154  and/or via a printed certificate or report. In accordance with an exemplary embodiment, component/gage selection algorithm  400 , predetermined calibration algorithm  500  and predetermined component measurement algorithm  600  are discussed in more detail below.  
         [0076]    Component/Gage Selection Algorithm  
         [0077]    Referring to FIG. 13, a block diagram of a component/gage selection algorithm  400  is shown and described. It should be noted that although component/gage selection algorithm  400  is described for component/gage selection screen  214  herein, as configured for a threaded product, component/gage selection algorithm  400  may be modified as required for various component selections.  
         [0078]    Referring to FIG. 14, upon starting inspection system  100 , a component/gage selection screen  200  is displayed to a system operator via display device  154 . Component/gage selection screen  200  is preferably created in a Graphical User Interface (GUI) format having a plurality of pull-down menus  202  and software buttons  204  that advantageously allow known physical characteristics of a component to be measured to be communicated to inspection system  100  via a mouse and/or keyboard. Pull-down menus  202  preferably include at least one of a component size selection pull down menu  206 , a TPI pull down menu  208 , a Class selection pull down menu  210  and a thread length pull down menu  211  and software buttons  204  preferably include at least one of a unit selection button  212 , a component selection button  214 , a set plug/work plug selection button  216  and a go/not go selection button  218 . It is contemplated that component selection button  214  advantageously allows for the selection of a plurality of types of components to be inspected, including a plain diameter gage, a threaded gage, a product, an X-calibration block, a Y-calibration block and a Roll. It is further contemplated that pull-down menus  202  and software buttons  204  are displayed to a system operator in a manner responsive to component selection button  214 .  
         [0079]    For example, referring to FIG. 15, if component selection button  214  is configured for a plain diameter gage, plurality of pull-down menus  202  and plurality of selection buttons  204  displayed to a system operator include at least one of a unit selection button  212  and a plain diameter gage size pull down-menu  213 . Referring to FIG. 16, if component selection button  214  is configured for a threaded gage, plurality of pull-down menus  202  and plurality of selection buttons  204  displayed to a system operator include at least one of unit selection button  212 , set plug/work plug selection button  216 , go/not go selection button  218 , component size selection pull down menu  206 , TPI pull down menu  208  and Class selection pull down menu  210 . Referring to FIG. 17, if component selection button  214  is configured for a threaded product, plurality of pull-down menus  202  and plurality of selection buttons  204  displayed to a system operator include at least one of a unit selection button  212 , set plug/work plug selection button  216 , go/not go selection button  218 , component size selection pull down menu  206 , TPI pull down menu  208 , Class selection pull down menu  210  and a thread length menu  211 . Additionally, when component selection button  214  is configured for a threaded product, a pitch diameter measurement menu  217  may be displayed. Referring to FIG. 18, a component/gage selection screen  202  is shown for component selection button  214  configured for a calibration block.  
         [0080]    In the case of a threaded component  162 , once component/gage selection screen  200  is displayed, the system operator selects the system of units inspection system  100  is to use when measuring threaded component  162 , such as English or Metric units, via unit selection button  212 , as shown in block  402 . The system operator then selects the type of component that inspection system  100  will be measuring (i.e. a threaded component), via gage/product selection button  214 , as shown in block  404 , and (in the case of a gage) whether it is a set plug or a work plug, via set plug/work plug selection button  216 , as shown in block  406 . Also in the case of a gage, once this has been accomplished, the system operator selects whether this is a go or not/go, via go/not go selection button  218 , and the gage size of the component is selected, via gage size selection pull-down menu  206 , as shown in block  408 . In the case of a component, the Threads Per Inch (TPI) and the Class of the component are then selected, via TPI pull down menu  208 , as shown in block  410  and Class selection pull down menu  210 , respectively, as shown in block  412 .  
         [0081]    Predetermined Calibration Algorithm  
         [0082]    Upon completion of the system startup procedure, inspection system  100  begins performing a system calibration procedure responsive to predetermined calibration algorithm  500 . Referring to FIG. 19 and FIG. 20, once the system calibration procedure has been initiated, positioning stage  128  is moved to a predetermined starting position, or HOME position, as shown in block  502 . It is contemplated that any location of positioning stage  128  may be selected as the HOME position. At this point, all encoders are zeroed and all positional measurements are determined with reference to this HOME position. An Arbor reference adjustment is then performed to properly locate the arbor reference “knee” position  220 , as shown in block  404 , wherein arbor reference “knee” position  220  is a notch disposed on at least one of first arbor  132  and/or second arbor  134 . A software “constraint window” or search box is created within the field of view of lens  138  and image data representing the image contained within this search box is then examined to locate arbor reference “knee” position  220 . Arbor reference “knee” position  220  may preferably be located by analyzing this image data for differences in pixel intensities to identify where the horizontal arbor surface ends and the vertical arbor surface begins. This vertical arbor surface is arbor reference “knee” position  220 . Once arbor reference “knee” position  220  is located, blue crosshairs  222  are disposed at arbor reference “knee” position  220  and displayed to the system operator via display device  154  to advantageously allow the system operator to visually confirm arbor reference “knee” position  220 . It should be stated that arbor reference “knee” position  220  must be contained with this search box for predetermined calibration algorithm to continue. If arbor reference “knee” position  220  is not disposed within the search box, predetermined calibration algorithm terminates.  
         [0083]    In accordance with an exemplary embodiment, the lens system distortion measurements are then conducted, as shown in block  506 . Referring to FIG. 21, this is preferably accomplished by operating inspection system  100  such that positioning stage  128  relocates arbor reference “knee” position  220  to four distinct position/locations within the field of view of lens  138  on the 0° side of at least one of first arbor  132  and/or second arbor  134 . These four distinct position/locations are located at a lower vertical field of view position  135 , a lower middle vertical field of view position  137 , a upper middle vertical field of view position  139  and an upper vertical field of view position  141 . At each of these four vertical locations, three horizontal measurements are made and include a left measurement  143 , a center measurement  145  and a right measurement  147 . This measurement data is preferably obtained by observing and/or analyzing the image data corresponding to the particular points of measurement. The results of this observation/analysis are then recorded for use in subsequent calculation. This sequence is then repeated on the 180° side of at least one of first arbor  132  and/or second arbor  134 . It is contemplated that a total of 24 measurements (i.e. 12 on the 0° side and 12 on the 180° side) are stored and thus, become part of the calculated lens distortion measurement performed near the end of the calibration cycle. As discussed above, the lens system distortion routine, and thus the distortion equations, is preferably provided by the manufacturer of lens system  138 .  
         [0084]    Once the lens system distortion measurements have been conducted, the X-Axis calibration is performed, as shown in block  508 . The X-Axis calibration may preferably be accomplished by locating the center position, the left extreme and the right extreme of field of view  230  of lens  138  and using these data points to calculate the inches per step, inches per pixel and/or the steps per inch calibration factors for the X-Axis. One way to determine center position, left extreme and right extreme of field of view  230  is to move arbor reference knee position  220  to the extreme left hand side of field of view  230  and register this location as the left extreme. Arbor reference knee position  220  is then moved to the extreme right hand side of field of view  230  and this location is registered as the right extreme. Arbor reference knee position  220  should then be moved to a point midway between the left extreme and the right extreme of field of view  230 . This point will be the center of field of view  230  and should be registered as the center position. This advantageously ensures minimal distortion from lens  138 .  
         [0085]    Upon completion of the X-Axis calibration, a Y-Axis calibration at the 1 st  0° diameter is performed, as shown in block  510 . The Y-Axis calibration at the 1 st  0° diameter is preferably accomplished by using the lower middle center location and upper middle center location obtained during the lens system distortion measurement to calculate the inches per step, inches per pixel and/or the steps per inch calibration factors for the Y-Axis. The lower middle vertical location is then determined and is used to measure the radius for the 0° side (which may later be added to the radius for the 180° side to determined the diameter of the arbor).  
         [0086]    Upon completion of the Y-Axis calibration at the 1 st  0° diameter, a Y-Axis 2 nd  0° diameter determination is performed, as shown in block  512 . The determination of the Y-Axis 2 nd  0° diameter is preferably accomplished by moving positioning stage  128  such that arbor reference knee position  220  on the 0° side of the arbor is disposed at a lower vertical location, a lower middle vertical location, an upper middle vertical location and an upper vertical location of field of view  230 . At each of these locations, inspection system  100  performs three horizontal measurements, a left horizontal measurement, a center horizontal measurement and a right horizontal measurement. This data is preferably stored and may become part of the calculated lens distortion factors determined toward the end of the calibration cycle. It should be noted that the lower middle vertical location may be the final position to be measured and may be used to measure the radius for the 180° side, which may later be added to the radius of the 0° side to determine the arbor diameter.  
         [0087]    Upon completion of the Y-Axis 2 nd  0° diameter determination, a Y-Axis 2 nd  diameter determination is performed, as shown in block  514 . The determination of the Y-Axis 2 nd  diameter is preferably accomplished by moving the left arbor reference location to determine the location of the arbor relative to the right arbor reference and lens  138 . A single measurement is taken in the center of field of view  230  to minimize distortion and is used to determine the radius and to compute the tangent correction factor that is used to compensate for any misalignment of the Y-Axis of positioning stage  128  with the Y-Axis of lens  138 .  
         [0088]    Once this has been completed, a Y-Axis 2 nd  180° diameter determination is performed, as shown in block  516 , by moving positioning stage  128  to the 180° side (same X-Axis position) to measure the radius. The Y-Axis tangent correction factor is then determined, as shown in block  518 . This advantageously compensates for a component that may be disposed between first arbor  132  and second arbor  134  in a non-level (i.e. horizontal) manner. Moreover, this may preferably be accomplished by using the measurements taken at the right and left sides of the arbor and both the X and Y measurement information from the encoders and the image measurement tools are used to compute the tangent correction factor. It should be noted that all subsequent Y-Axis measurements include this compensation factor. All of the information obtained above are then used to determine the lens distortion factor, as shown in block  520 , which is then used for all subsequent X and Y measurements, including any light source and/or system stage positional distortions/errors (i.e. Abbe* stage errors).  
         [0089]    Predetermined Component Measurement Algorithm  
         [0090]    It is contemplated that predetermined component measurement algorithm  600  is responsive to the component being measured. As such, predetermined component measurement algorithm  600  is explained for various types of components to be measured and includes a threaded product and a threaded gage. It will be appreciated that all measurements are preferably conducted by observing and/or analyzing image data to determine desired points of interest on threaded component  162 , such as the thread ridges and grooves. These points of interest are preferably located by examining the image data and identifying variations in pixel intensities to establish silhouette edge points of threaded component  162 . Once these points of interest have been identified, desired physical characteristics of threaded component  162  may be determined using known mathematical, geometric and/or trigonometric relationships.  
         [0091]    Upon completion of predetermined calibration algorithm  500 , positioning stage  128  is positioned back to arbor reference knee position  220  and component measurement algorithm  600  is initiated, as shown FIG. 22. At this point, the Flank registration is performed, as shown in block  602 . This is preferably accomplished by disposing positioning stage  128  such that component  162  is positioned to an initial X and Y location by moving positioning stage  128  one half inch away from arbor reference knee position  220  in the X direction and toward component  162 . Positioning stage  128  is then moved in the Y direction such that the lower limit of the pitch diameter at the centerline of field of view  230  is approximated. A software measurement tool is then placed at the centerline to find the flank angel crossings at the centerline. The stage is then moved again away from arbor reference knee position  220  in the X-axis direction to align the minor diameter with the left edge of field of view  230 . All subsequent measurements rely on moving in pitch lead increments in the X-axis direction. It should be noted that the pitch lead increments are determined by the component selection and are published at the top of the Lead Standards readouts. It will be appreciated that, for threaded gages, the truncated measurements will be conducted at thread #2 and the full form measurements will be conducted at thread #6. The term 4X refers to the number of threads for the third lead measurement and indicates that it is being made over a span of four threads and the term /10 indicates that there are ten threads available on this component.  
         [0092]    Once the flank registration has been performed, the 1 st  full thread 0° side truncated measurements are conducted, as shown in block  604 . This may preferably be accomplished by repositioning positioning stage  128  on the first thread on the 0° side designated as the truncated thread location. This designation is dependent upon the thread numbers and thus upon the selection of component  162 . Using the silhouette image data, processing device  152  then determines the minor radius, the major radius (for set plug only), the pitch radius, the lead pitch, the lead/trail flank angles and the included angles. The major radius is determined via the major diameter, which is a composite measurement based on the major radius of the 0° and corresponding 180° side of the threads. Thus, the major radius is determined by summing the individual measurements along the thread flat and dividing by the number of measurements collected. The number of measurement locations may be determined by taking 70% of the thread width, as determined by predetermined thread tables, and centering them on the center of the thread. This major radius average is then combined from both the 0° and the 180° sides to get the major diameter. For a gage, this process is performed for both truncated and full form locations and for a product, this process is performed only for the full form location.  
         [0093]    The pitch diameter calculation (for both truncated and full form location), which is based on the leading and trailing angles, major diameter, pitch lead and crest width at the location in question (i.e. truncated or full form), may be determined by the equation:  
           PD=MD −( Cot ( PL/ 2)− CW ),  
         [0094]    Where, PD is pitch diameter, MD is major diameter, PL is pitch lead and CW is crest width. The lead front measurement, which is responsive to the difference between the groove distance and the ridge distance along the leading/trailing/leading flanks may be determined by positioning a software measurement tool along the X-axis and moving the tool vertically around the pitch diameter until the groove distance minus the ridge distance is minimized. The tool is then repositioned at the minimized location and the groove distance and the ridge distance are added to determine the lead front. The lead back measurement, which is responsive to the difference between the groove distance and the ridge distance along the trailing/leading/trailing flanks may similarly be determined by positioning a software measurement tool along the X-axis and moving the tool vertically around the pitch diameter until the groove distance minus the ridge distance is minimized. The tool is then repositioned at the minimized location and the groove distance and the ridge distance are added to determine the lead back.  
         [0095]    The multi thread lead, which is responsive to the distance between the lead front and the lead back measurements, may now be determined. Additionally, the lead angle may be determined by an optimistic theoretical line of best fit along the leading flanks of the thread on the 0° side at the truncated location. The trailing angle may be determined by an optimistic theoretical line of best fit along the trailing flanks of the thread on the 0° side at the truncated location. The included angle may then be determined by adding the leading angle and trailing angle.  
         [0096]    At this point, the 2 nd  thread 0° side full form measurements are then made, as shown in block  606 . This preferably may be accomplished by repositioning positioning stage  128  on the second thread on the 0° side designated as the full form thread location. As discussed above, this designation is dependent upon the thread numbers and thus upon the selection of component  162 . Using the silhouette image data, processing device  152  then determines the minor radius, the major radius, the pitch radius and the lead pitch.  
         [0097]    The 1 st  full thread 180° side truncated measurements are then conducted, as shown in block  608 , and are preferably accomplished by repositioning positioning stage  128  on the first thread on the 180° side designated as the truncated thread location. Using the silhouette image data, processing device  152  then determines the minor radius, the major radius (for set plug only), the pitch radius and the lead pitch.  
         [0098]    The 2 nd  thread 180° side full form measurements are then made, as shown in block  610 . This is preferably accomplished by repositioning positioning stage  128  on the second thread on the 180° side designated as the full form thread location. Using the silhouette image data, processing device  152  then determines the major radius, the pitch radius and the lead pitch.  
         [0099]    The component values and limits are then updated and the results are displayed to a system operator and/or printed out in certificate form and positioning stage  128  is repositioned to arbor reference knee position  220 , as shown in block  612 .  
         [0100]    It is further contemplated that inspection system  100  may perform an R&amp;R (reliability &amp; repeatability) measurement procedure in a manner responsive to a predetermined R&amp;R algorithm  700 . Referring to FIG. 23, a block diagram illustrating predetermined R&amp;R algorithm  700  is shown and discussed. Upon initiation of predetermined R&amp;R algorithm  700 , positioning stage  128  is positioned into the load position and component  162  is disposed to be retained between first arbor  132  and second arbor  134 , as shown in block  702 . R&amp;R algorithm  700  is then activated, as shown in block  704 . As discussed hereinabove, inspection system  100  then performs predetermined calibration algorithm  500  and predetermined component measurement algorithm  600 , as shown in block  706 . At this point, once predetermined component measurement algorithm  600  has been completed, the system operator may elect to have inspection system  100  pause every seven cycles for rotation of component  162 , as shown in block  708 . The measurement cycle may then repeated as many times as desired and the results may then be displayed to the system operator via display device  154  or via a printed certificate or report, as shown in block  710 .  
         [0101]    It will be appreciated that the measurements described hereinabove for lens distortion analysis, predetermined calibration algorithm  500 , predetermined component measurement algorithm  600  and/or R&amp;R algorithm  700  are preferably accomplished by examining the image data for pixel intensity. This advantageously allows inspection system  100  to locate and record known positions on lens  138 , first arbor  132 , second arbor  134  and/or component  162  as data points. Using these data points, the physical characteristics of lens  138 , first arbor  132 , second arbor  134  and/or component  162  may be calculated via any method suitable to the desired end purpose, such as geometric/trigonometric relations, estimations and/or predictions.  
         [0102]    In accordance with an exemplary embodiment, it is contemplated that multiple measurements may be made at each of the measurement locations in a manner responsive to predetermined component thread specifications. Moreover, the image data is preferably processed to comprise a plurality of discrete pixel elements. Processing device  142  then conducts each of the measurements by examining each pixel of the plurality of discrete pixel elements to determine the physical characteristics of component  154  as discussed hereinabove. It is further contemplated that image data may be displayed via any display device suitable to the desired end purpose, such as a paper printout, a computer screen, a television, a plasma display and/or a Liquid Crystal Display (LCD). Although the component physical characteristics are determined by processing the image data as discussed hereinabove, the component physical characteristics may be determined by processing the image data using any device and/or method suitable to the desired end purpose. Inspection system  100  may also be operated and/or monitored via a network connection, such as a wireless network (cellular, pager, RF), Local Area Network, Wide Area Network, Ethernet and/or Modem.  
         [0103]    It is contemplated that processing device  152  may store image data and measurement results in a data storage device and/or a volatile memory of processing device  152  (e.g. RAM). It should also be noted that image data may be stored in a volatile and/or a non-volatile memory location which may be disposed in any location suitable to the desired end purpose, such as a remote server. In addition, the data storage device may be used to store individual component data and/or group component data which may be specific to a desired purpose, such as data for a specific user, component part and/or a specific end user device, wherein the component data may include a large range of information, such as user specific data and/or component part history data.  
         [0104]    In accordance with an exemplary embodiment, inspection system  100  may advantageously be self-calibrating and automated for inspection of multiple components. Moreover, inspection system  100  advantageously allows for non-contact measurements which reduce and/or eliminate high inspection costs, operator feel, fatigue, uncertainties and/or error. Inspection system  100  advantageously allows for the generation of automatic certificates and information output files. Moreover, inspection system  100  advantageously includes built-in repeatability and reliability (R&amp;R) qualification and testing programs and advantageously allows for an extremely fast measurement cycle. The measurement and reporting cycles are typically performed in less than two minutes duration. Furthermore, inspection system  100  advantageously has an accuracy of about 0.000020 or less. This could never be realized using the current “Attributes” or variables measuring system. Also, inspection system  100  is about 25 times faster than using an “Attributes” or variables measuring system, which will only measure one of the multiple component characteristics required for inspection to satisfy current specifications.  
         [0105]    A machine-readable computer program code and/or a medium encoded with a machine-readable computer program code for measuring the characteristics of component  162  using inspection system  100 , the code and/or medium including instructions for causing a controller to implement a method including operating inspection system  100 , wherein inspection system  100  includes collimated light source  102 , a sensing device  104  optically communicated with collimated light source  102  and processing device  152 , wherein processing device  152  is communicated with the sensing device  104 , disposing component  162  such that component  162  is associated with inspection system  100 , positioning component  162  such that component  162  is disposed to partially impede the optical communication between the sensing device  104  and the collimated light source  102 , operating the collimated light source  102  such that a collimated light beam is incident upon component  162  to cause a silhouette of component  162  to be received by the sensing device  104 , wherein the sensing device  104  generates image data responsive to the silhouette, communicating the image data to processing device  152 , processing the image data to determine desired characteristics of component  162  and displaying the characteristics to a user.  
         [0106]    In accordance with an exemplary embodiment, the processing of FIGS.  12 - 13 , FIG. 19 and FIGS.  22 - 23  may be implemented by a controller disposed internal, external or internally and externally to inspection system  100 . In addition, processing of FIGS.  12 - 13 , FIG. 19 and FIGS.  22 - 23  may be implemented through a controller operating in response to a computer program. In order to perform the prescribed functions and desired processing, as well as the computations therefore (e.g. execution control algorithm(s), the control processes prescribed herein, and the like), the controller may includes, but not be limited to, a processor(s), computer(s), memory, storage, register(s), timing, interrupt(s), communication interface(s), and input/output signal interface(s), as well as combination comprising at least one of the foregoing.  
         [0107]    The invention may be embodied in the form of a computer or controller implemented processes. The invention may also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, and/or any other computer-readable medium, wherein when the computer program code is loaded into and executed by a computer or controller, the computer or controller becomes an apparatus for practicing the invention. The invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer or controller, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein when the computer program code is loaded into and executed by a computer or a controller, the computer or controller becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor the computer program code segments may configure the microprocessor to create specific logic circuits.  
         [0108]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, may modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.