High speed method and system for inspecting a stream of parts at a pair of inspection stations

A high-speed system for inspecting a stream of parts at a separated pair of sequential inspection stations and sorting the inspected parts, the system comprising:

• a part transfer subsystem to controllably receive a stream of parts in rapid succession at a load station, the subsystem including a conveyor to consecutively convey the received parts so the parts travel along a path which extends from the load station and through a first inspection station having a first measurement axis and through a second sequential inspection station having a second measurement axis;
• a first array of backside illumination assemblies angularly-spaced about the first measurement axis to direct a first array of angularly-spaced beams of collimated radiation at an outer peripheral surface of the part from a first side of the path when the part is conveyed through the first inspection station to create a corresponding first array of unobstructed portions of the beams passing by and not blocked by the part;
• a first array of lens and detector assemblies angularly-spaced about the first measurement axis to detect the first array of unobstructed portions at a first plurality of angularly-spaced imaging locations on a second side of the path opposite the first side of the path at the first inspection station to obtain a first set of electrical signals;
• a second array of backside illumination assemblies angularly-spaced about the second measurement axis to direct a second array of angularly-spaced beams of collimated radiation at the outer peripheral surface of the part from the second side of the path when the part is conveyed through the second inspection station to create a corresponding second array of unobstructed portions of the beams passing by and not blocked by the part;
• a second array of lens and detector assemblies angularly-spaced about the second measurement axis to detect the second array of unobstructed portions at a second plurality of angularly-spaced imaging locations on the first side of the path at the second inspection station to obtain a second set of electrical signals;
• at least one processor to process the first and second sets of electrical signals to identify parts having an unacceptable geometric dimension;
• a mechanism including a part sorter to direct parts identified as having an unacceptable geometric dimension to a defective part area and directing parts not identified as having an unacceptable geometric dimension to an acceptable part area;
• and
• a system controller coupled to the at least one processor and the part sorter to control the sorting based on the inspecting.