Work support system and work support method

Patent metadata

Field	Value
Publication number	US-11118899-B2
Application number	US-201816753124-A
Country	US
Kind code	B2
Filing date	Oct 11, 2018
Priority date	Nov 2, 2017
Publication date	Sep 14, 2021
Grant date	Sep 14, 2021

Abstract

A work support system includes a measurement apparatus measuring a state of each of multiple measurement points on an object surface of a workpiece, a projector apparatus, and an arithmetic apparatus creating a projection image of the projector apparatus based on a measurement result of the measurement apparatus. The arithmetic apparatus calculates a difference between a state measured by the measurement apparatus and a target state for each of the multiple measurement points, and creates the projection image such that a picture of a characteristic point representative of the difference at each of the multiple measurement points is projected by the projector apparatus at a position of a corresponding measurement point on the object surface of the workpiece.

First claim

The invention claimed is:

1. A work support system supporting a worker's work on a workpiece, the work support system comprising:
a measurement apparatus measuring a position of each of multiple measurement points on an object surface of the workpiece;
a projector apparatus arranged at a position different from the measurement apparatus such that the object surface is present within a projection range; and
an arithmetic apparatus creating a projection image of the projector apparatus based on a measurement result of the measurement apparatus, wherein
the arithmetic apparatus calculates a difference between a shape measured by the measurement apparatus and a target shape for each of the multiple measurement points,
the arithmetic apparatus creates the projection image such that a picture of a characteristic point representative of the difference for each of the multiple measurement points is projected by the projector apparatus at a position for a corresponding measurement point on the object surface of the workpiece, and
the arithmetic apparatus includes
a difference map creating part calculating the difference between the shape measured by the measurement apparatus and the target shape for each of the multiple measurement points and creating a first difference map from the viewpoint of the measurement apparatus acquired by imaging a distribution of difference on the object surface as an image on a first plane orthogonal to a first view direction of the measurement apparatus to the object surface,
a difference map converting part performing image conversion of the first difference map based on a positional relationship between the measurement apparatus and the projector apparatus into an image on a second plane orthogonal to a second view direction of the projector apparatus to the object surface and thereby creating a second difference map from the viewpoint of the projector apparatus, and
a projection image creating part creating the projection image including the second difference map so that a picture of the second difference map is overlaid on the object surface.

2. The work support system according to claim 1 , wherein the arithmetic apparatus includes a projection image correcting part correcting the projection image through image conversion so that the picture of the second difference map is overlaid in a matched manner on the object surface.

3. The work support system according to claim 2 , wherein
the arithmetic apparatus includes
an input part for the worker adjusting the projection image so that the picture of the second difference map is overlaid in a matched manner on the object surface, and
a correction conversion matrix calculating part calculating an image conversion matrix used for image conversion of the projection image based on the projection image before being adjusted by the worker and the projection image after being adjusted.

4. The work support system according to claim 3 , comprising at least four markers detachably attached to the object surface and used as a reference for alignment for the worker overlaying the picture of the second difference map in a matched manner on the object surface.

5. A work support system supporting a worker's work on a workpiece, the work support system comprising:
a measurement apparatus measuring a position of each of multiple measurement points on an object surface of the workpiece;
a projector apparatus arranged at a position different from the measurement apparatus such that the object surface is present within a projection range; and
an arithmetic apparatus creating a projection image of the projector apparatus based on a measurement result of the measurement apparatus, wherein
the arithmetic apparatus calculates a difference between a shape measured by the measurement apparatus and a target shape for each of the multiple measurement points,
the arithmetic apparatus creates the projection image such that a picture of a characteristic point representative of the difference for each of the multiple measurement points is projected by the projector apparatus at a position for a corresponding measurement point on the object surface of the workpiece, and
the arithmetic apparatus includes
a difference calculating part calculating the difference between the shape measured by the measurement apparatus and the target shape for each of the multiple measurement points,
a 3D model creating part creating a 3D model of the workpiece having the shape measured by the measurement apparatus,
a texture creating part creating a texture of the 3D model in which a characteristic point representative of the difference at each of the multiple measurement points is drawn at the position for the corresponding measurement point on the 3D model,
a 3D model image creating part setting a viewpoint for the 3D model so as to achieve the same positional relationship as the positional relationship of the projector apparatus relative to the workpiece, and creating a two-dimensional picture of the 3D model viewed from the viewpoint, and
a projection image creating part creating the projection image including the two-dimensional picture of the 3D model such that the two-dimensional picture of the 3D model is overlaid on the workpiece.

6. The work support system according to claim 1 , wherein the measurement apparatus is a three-dimensional measurement apparatus measuring the position of each of the multiple measurement points on the object surface of the workpiece.

7. The work support system according to claim 6 , wherein
the projector apparatus is arranged in a measurement range of the three-dimensional measurement apparatus, and wherein
the arithmetic apparatus calculates a positional relationship between the three-dimensional measurement apparatus and the projector apparatus based on a position of the projector apparatus measured by the three-dimensional measurement apparatus.

8. A work support method of supporting a worker's work on a workpiece, the work support method comprising:
measuring a position of each of multiple measurement points on an object surface of the workpiece with a measurement apparatus; and
creating, based on a measurement result of the measurement apparatus, a projection image of a projector apparatus arranged at a position different from the measurement apparatus such that the object surface is present within a projection range, wherein
the projection image is created by
calculating a difference between a shape measured by the measurement apparatus and a target shape for each of the multiple measurement points,
creating the projection image such that a picture of a characteristic point representative of the difference for each of the multiple measurement points is projected by the projector apparatus at a position for a corresponding measurement point on the object surface of the workpiece,
creating a first difference map from the viewpoint of the measurement apparatus acquired by imaging a distribution of the difference on the object surface as an image on a first plane orthogonal to a first view direction of the measurement apparatus to the object surface,
performing image conversion of the first difference map based on a positional relationship between the measurement apparatus and the projector apparatus into an image on a second plane orthogonal to a second view direction of the projector apparatus to the object surface and thereby creating a second difference map from the viewpoint of the projector apparatus, and
creating the projection image including the second difference map so that a picture of the second difference map is overlaid on the object surface.

9. The work support method according to claim 8 , wherein the projection image is corre

Assignees

• Kawasaki Heavy Ind Ltd

Inventors

• Nakagawa Atsuki
• Nakamura Naohiro
• Iwamoto Masahiro
• Shikoda Shigekazu

Classifications

• B21D22/18

  using tools guided to produce the required profile · CPC title

• H04N9/31

  Projection devices for colour picture display {, e.g. using electronic spatial light modulators [ESLM]} · CPC title

• G01B21/20

  for measuring contours or curvatures, e.g. determining profile · CPC title

• H04N9/3194 Primary

  including sensor feedback · CPC title

• H04N9/3185

  Geometric adjustment, e.g. keystone or convergence (optical or mechanical adjustment of convergence H04N9/317; using scanning means H04N3/22; optical or mechanical adjustments of projectors not peculiar to the presence of an electronic spatial light modulator G03B21/14) · CPC title