Here is an actual size close up of a door handle. You should understand now how much image data is gathered for single scan of a vehicle. The total amount of image data collected for a single vehicle is approximately 400 Meg, or, almost this size of a CD-ROM!





RepairMan can take all four images from PSI. Due to the specialized laser scanning equipment, all four images have exactly the same size, position, and shape. Therefore only one calibration procedure is needed for setup of the entire system. Shown here is another one of the images taken from PSI. Notice how similar in shape size and position the this image is with the one above.





RepairMan can create a mask used for eliminating invalid defect data. It is also used for classifying defects into zones. It is also used to determine the repairability of defects by a robot.

Shown in the middle is a new blank mask. This new mask is all black. It will mask out all defects that come from PSI.





Using the mouse, zones are chosen where defects will be accepted. RepairMan numbers the zones for classification. Each zone can be given a name like "rear door middle" for zone 5.

White areas on the mask allow defects to be accepted.





Two masks are maintained by RepairMan. The white mask indicated defects that can be repaired by a robot. The grey mask indicates where defects can be detected, but can not be repaired by a robot.

The black areas between the zones indicate where defects can not be distinguished from edge features. The size of the black areas is defined by an edge tolerance, which has been exaggerated here for illustration purposes.

This mask is not finished yet. The white mask does not yet take into consideration the shape of a sanding disk.





The mask images can be saved to BMP image files and then read back in for manual modification outside of RepairMan.

The edge tolerance can be changed also. Notice the "Tool Radius" value. This value represents the radius of a circular sanding disk that is attached to a robot.





With the tolerances and the tool radius set, it's time to generate the final mask. The final mask generation algorithm figures out where a circular sanding disk is able to fit onto the vehicle without touching any edges.





Here is the result. The white areas show where defects can be repaired by a robot. The grey areas show where defects can be reported by RepairMan but can not be repaired by a robot.


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