Apparatus and method for detecting non-conformities in manufactured products

Abstract

Apparatuses, computer program products, and methods are described herein for detecting non-conformities in manufactured products. The apparatus comprises a mandrel, a light emitter for radiating light energy, an imaging device positioned adjacent the mandrel and structured to acquire an image of the product. The imaging device comprises a support device, a camera secured to the support device, a photo sensor for reading the lux value of the light energy reflected by the product, and a controller. The controller stores a predetermined lux value, receives data from photo sensor representing the lux value, compares the lux value to the predetermined lux value, and transmits instructions to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value.

Description

APPARATUS AND METHOD FOR DETECTING NON-CONFORMITIES IN MANUFACTURED PRODUCTSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Patent Application No. 63 / 469,892, filed May 31, 2023, the entire contents of which are hereby incorporated by reference.FIELD

[0002] The present invention relates to an apparatus for detecting non-conformities in manufactured products and a method of use.BACKGROUND

[0003] Existing implementations of inspection of non-conformities in manufactured products utilize a stationary camera to capture light energy. However, these implementations are ineffective at capturing high quality images of products with dimensions that vary as a result of the manufacturing process or products that are in motion during non-conformity detection. As a result, the accuracy of detecting non-conformities varies greatly from one sample of a product to the next, often resulting in the incorrect assessment of the quality of manufactured products. As such, there is a need for an apparatus and method for detecting non-conformities in manufactured products.SUMMARY

[0001] The following presents a simplified summary of one or more embodiments of the present invention, in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments of the present invention in a simplified form as a prelude to the more detailed description that is presented later.

[0002] In one aspect, an apparatus for detecting non-conformities in a product is presented. The apparatus may include a mandrel structured to secure the product, a light emitter for radiating light energy, wherein the light emitter is positioned adjacent the mandrel so that the light emitterradiates light energy onto the product secured by the mandrel, an imaging device positioned adjacent the mandrel and structured to acquire an image of the product, the imaging device comprising a support device, a camera secured to the support device, wherein the support device is structured to move the camera, a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel, a controller, the controller comprising a processor and a non-transitory computer readable storage medium for storing at least one computer instruction, the controller being in operable communication with a support device, camera, and photo sensor and wherein the at least one computer instruction is used to perform storing a predetermined lux value, receiving data from photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel, comparing the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value, and transmitting instructions to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value.

[0003] In some embodiments, the imaging device may include a position sensor structured to determine a relative position of the camera to the mandrel.

[0004] In some embodiments, the controller may be further in operable communication with the position sensor, and wherein the at least one computer instruction is used to perform receiving data from the position sensor representing the relative position of the camera to the mandrel.

[0005] In some embodiments, the support device may include a transfer device structured to receive the product.

[0006] In some embodiments, the transfer device may include a suction cup.

[0007] In some embodiments, the mandrel may be structured to rotate the product.

[0008] In some embodiments, the at least one computer instruction may be further used to perform receiving at a recurring predetermined interval additional data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel, comparing at each of the recurring predetermined intervals the data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel to the predetermined lux value, and transmitting instructions at each of the recurring predetermined intervals to the support device to move the camera relative to the mandrel when the lux value ofthe light energy reflected by the product secured on the mandrel differs from the predetermined lux value, wherein a distance of the movement of the camera relative to the mandrel is determined based on a difference between the lux value of the light energy reflected by the product secured on the mandrel and the predetermined lux value for the corresponding recurring predetermined interval.

[0009] In another aspect, a computer program product for detecting non-conformities in a product is presented. The computer program product may include a controller comprising a non- transitory computer-readable medium including at least one computer instruction, the controller being in operable communication with a support device, camera, and photo sensor and wherein the at least one computer instruction is used to store a predetermined lux value, receive data from a photo sensor of an imaging device representing a lux value of a light energy reflected by a product secured on a mandrel structured to secure the product from a light emitter, wherein the light emitter is positioned adjacent the mandrel so that the light emitter radiates light energy onto the product secured by the mandrel, wherein the imaging device is positioned adjacent the mandrel and structured to acquire an image of the product, and wherein the imaging device may include a support device, a camera secured to the support device, wherein the support device is structured to move the camera, a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel, and a controller, the controller being in operable communication with the support device, camera, and photo sensor, compare the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value, and transmit instructions to a support device to move a camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value.

[0010] In yet another aspect, a method for detecting non-conformities in a product is presented. The method may include storing a predetermined lux value, receiving data from a photo sensor of an imaging device representing a lux value of a light energy reflected by a product secured on a mandrel from a light emitter for radiating light energy, wherein the light emitter is positioned adjacent the mandrel so that the light emitter radiates light energy onto the product secured by the mandrel, comparing the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value, and transmitting instructions to a support device to move a camera relative to a mandrel when thelux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value, wherein the mandrel is structured to secure the product, wherein the imaging device is positioned adjacent the mandrel and structured to acquire an image of the product, the imaging device comprising a support device, a camera secured to the support device, and wherein the support device is structured to move the camera, a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings, wherein:

[0012] Figure 1 illustrates a perspective view of an apparatus for detecting nonconformities in products, according to one embodiment of the present invention;

[0013] Figure 2 illustrates a perspective view of an apparatus for detecting nonconformities in products, according to one embodiment of the present invention;

[0014] Figure 3 illustrates a perspective view of an apparatus for detecting non- conformities in products, according to the embodiment of Figure 2;

[0015] Figure 4 illustrates technical components of an exemplary controller for detecting non-conformities in products, in accordance with an embodiment of the invention; and

[0016] Figure 5 illustrates a process flow for detecting non-conformities in products, according to one embodiment of the present invention.DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0017] Embodiments of the present invention now may be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and / or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on”something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on.”

[0018] Additionally, certain terminology is used herein for convenience only and is not to be interpreted as a limitation on the embodiments described. For example, the words “top,” “bottom,” “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configurations as depicted in the figures. Indeed, the referenced components in the figures may be oriented in any direction, unless specified otherwise, the configurative terminology used herein should be understood as encompassing such variations.

[0019] It should also be understood that “operable communication” or “operably coupled” as used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled together. Furthermore, “operable communication” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled together. Furthermore, “operable communication” or “operable coupled” may mean that the components are detachable from each other, or that they are permanently coupled together. Furthermore, components in operable communication may mean that the components retain at least some freedom of movement in one or more directions or may be rotated about an axis (i.e., rotationally coupled, pivotally coupled). Furthermore, “operable communication” or “operably coupled” may mean that components may be electronically connected and / or in fluid communication with one another.

[0020] Embodiments of the invention are directed to an apparatus for detecting nonconformities in manufactured products and a method of use of said apparatus. The apparatus and method described herein allows for the detection of non-conformities in products by actively monitoring and adjusting the position of the imaging device based on (i) the lux value of the light energy reaching the imaging device as reflected from the product, and / or (ii) the focal length of the imaging device relative the product. The technical features of the apparatus provide a novel approach to the capturing of image data to image clarity and subsequent detection of nonconformities obtained by algorithmic image processing. For example, the apparatus improves upon the traditional imaging devices and methodologies by actively positioning the imaging device relative the product to maintain the requisite amount of lux and / or focal length required for desired image clarity. This may be accomplished through a closed-loop feedback algorithm. Unliketraditional imaging systems that rely on capturing of the image subject to the available lux and / or focal length relative the product, the present apparatus and method may utilize a known coordinate position of the imaging device relative the product, determine differences between variables (such as lux and / or focal length) and predefined target variables of the same, and reposition the imaging device accordingly.

[0021] Figures 1 and 2 illustrate perspective views of an apparatus 100 for detecting nonconformities in products, according to one embodiment of the present invention.

[0022] After the production or receipt of a manufactured product, the inspection thereof is important to ensure the quality of the product, such that only desired products are accepted, and manufacturing processes may be adjusted to improve subsequent product manufacturing. Accordingly, such products may be subjected to the apparatus 100, where image(s) of the products are obtained by an imaging device and are subsequently received by controllers and / or one or more computer systems to algorithmically analyze the image(s) and / or control the type of images captured by the imaging device to detect non-conformities.

[0023] Exemplary algorithmic image processing methods as implemented herein are described in detail in at least U.S. Patents 10,560,634 and 10,508,994. Methods for obtaining the shape of a product include deflectometry, phase shift methods, stereo methods, lens focus methods, light sectioning methods, optical radar methods, interference methods, and TOF methods. The method for acquiring a shape image of a workpiece using deflectometry involves imaging a line of the workpiece using a camera and processing the resulting image to obtain a phase map. The process may involve illuminating the workpiece with eight different illumination patterns and capturing the resulting images, which are then processed to obtain diffuse and specular reflection components as well as phase components. Contrast corrections are then performed on the diffuse and specular reflection components, and a reference plane is used to calculate differences in the phase components, resulting in a phase map. The resulting image is then hierarchized to obtain a hierarchical diffuse albedo image, a hierarchical specular albedo image, and hierarchical phase images. Finally, a depth contour image is obtained for the phase map using a gradient operation. This method allows for accurate and efficient imaging of workpieces, with the ability to assist in camera and illuminating section positioning. The camera captures images of the workpiece as it moves past the camera, and the images are analyzed to identify any flaws or defects. The phase X and phase Y images obtained from the camera show shifts in phase that indicate changes in theshape of the workpiece. By stacking the phase changes, a shape image can be generated that highlights areas of the workpiece that have changed. Similarly, a depth contour image can be generated by calculating the distance from a reference plane to the workpiece surface. The procedure for setting the imaging conditions involves optical axis adjustment and setting the line scan interval, which determines the imaging timing of the camera.

[0024] The product 118 is exemplified in Figure 1 as a cylindrical body of a bottle assembly, however it will be appreciated that product 118 may be embodied as any number of shapes, including but not limited to: cubes, cuboids, spheres, cones, pyramids, prisms, curved shapes, or any combination thereof. Accordingly, it shall be appreciated that each unique shape of product 118 may lend itself to requiring a certain amount of light energy passing from the product 118 into the imaging device (“lux value”) in order for the imaging device to maximize the image clarity and resolution of the product 118. “Lux” or “lux value” may refer to the unit of measure of illumination, or luminous flux per unit area, to quantify the intensity of a light energy. A lux value (“lx”) is equal to one lumen per square meter (e.g., 1 lx = 1 lm / m2). Accordingly, a predetermined target lux value may be selected depending on the product 118 selected for the detection of non-conformities. Moreover, for each unique shape of product 118, it shall be appreciated that the distance from each surface of the product 118 to the imaging device may vary such as to present the entirety of product 118 into the field of vision of the imaging device. Accordingly, a predetermined target focal length of the imaging device may be selected depending on the product 118 selected for the detection of non-conformities.

[0025] To obtain images of the product 118, the product may be first placed in a receiver 116 of a mandrel 106. The receiver 116 is structured with geometry to matingly engage with a portion of the product 118 such that the product remains stable throughout the imaging process.

[0026] In some embodiments, mandrel 106 is structured to rotate the product 118 at a predetermined rotational speed using rotator 120 coupled to the mandrel 106. In this way, electrical energy may be supplied to a motor of the rotator 120, thereby rotating the product 118. In some embodiments, the electrical energy (e.g., current) and resulting speed of rotator 120 may be controlled using a controller comprising one or more power supplies, drives, and relays, and integrated and controlled by programming logic control (“PLC”), as will be described in detail herein with respect to Figure 4.

[0027] Although the mandrel 106 is depicted in Figures 1 and 2 as being mechanically coupled to a mounting unit 119 oriented in a vertical direction, it shall be appreciated that mandrel 106 may be positioned in numerous orientations to accommodate the individual requirements for each product 118 and processing layouts of various manufacturing facilities.

[0028] Adjacent the mandrel 106 may be a light emitter 114 for radiating light energy onto the product 118. The light emitter 114 is positioned adjacent the mandrel 106 so that the light emitter 114 radiates light energy onto the product 118 secured by the mandrel 106. In some embodiments, the light emitter 114 may be a typical fluorescent, incandescent, halogen, lightemitting-diode (“LED”) lamp assembly structured to emit light in a static configuration (e.g., either “on” or “off’). However, in other embodiments, the light emitter 114 may use the fluorescent, incandescent, halogen, LED lamp assembly to perform structured illumination, such as that found in the Keyence Lumitrax system, which projects a pattern of light onto the product 118. This pattern of light is designed to provide information about the surface of the object, which can then be used to enhance the image quality and improve measurement accuracy via the algorithmic image processing method described previously. Different types of structured illumination patterns may be used depending on the specific application and product 118 being inspected. Commonly used patterns include sinusoidal gratings, checkerboards, and stripes. These patterns are typically projected onto the product 118 at oblique angles, which allows for the capture of detailed surface information of the product 118 that would otherwise not be visible with traditional lighting processes.

[0029] An imaging device 102 may be positioned adjacent the mandrel 106 and be structured to acquire an image of the product 118. In some embodiments, the imaging device comprises a support device 108. In some embodiments, the support device 108 (as depicted in Figure 1) is a six-axis robotic arm which includes three linear axes, allowing the support device 108 to move up and down, left and right, and forward and backward, and three rotational axes, which allow the support device 108 to rotate around each of these directions. These axes of motion are controlled by a system of motors, sensors, and actuators in operatively coupled to the controller. Instead of the six degrees of freedom afforded by a six-axis robotic arm, in other embodiments the support device 108 may be an assembly with two, three, four, five, or seven degrees of freedom, with each axis corresponding to a degree of freedom controlled by a system of motors, sensors, and actuators in operatively coupled to the controller.

[0030] In some embodiments, the imaging device 102 includes a camera 112 secured to the support device 108, such that the support device 102 is structured to move the camera 112. In some embodiments, camera 112 is a line camera that captures images along a single line of pixels. The camera 112 consists of a linear array of photodiodes (e.g., a photo sensor) that convert light into electrical signals, which are then processed to create a high-resolution image. The photo sensor is structured to determine the lux value of the light energy reflected by the product 118 secured on the mandrel 106. In other embodiments, the camera 112 may be an area scan camera, 3D camera, hyperspectral camera, or any other suitable device for capturing an image of the product 118.

[0031] In some embodiments, the imaging device 102 further comprises a position sensor 115 structured to determine the relative position of the camera to the mandrel. In some embodiments, the position sensor 115 may be a gyroscope, which measures angular velocity, or the rate of rotation around an axis. The angular position of the imaging device 102 at the location of the position sensor 115 may be determined by integrating the angular velocity to determine angular position. Additionally, or alternatively, position sensor 115 may include an accelerometer or magnetometer to measure acceleration or changes in velocity by detecting changes in capacitance or piezoelectricity or changes in magnetic fields, respectively, to determine the location of the position sensor 115. In yet additional embodiments, a global positioning system (“GPS”) may be used to determine the location of the position sensor 115. By determining the location of the position sensor 115, the location of the position sensor 115 relative to the mandrel 106, light emitter 114, mounting unit 119, or any other object to which the imaging device 102 should calculate relative distance or avoid during movement.

[0032] Referring now to Figure 3, which illustrates a perspective view of another embodiment of an apparatus for detecting non-conformities in products, the support device 108 of the imaging device 102 may also include a transfer device 302, such as to securely collect the product 118 from a first position, such as a conveyor assembly, bin, or collection jig 308 and place the product 118 on the mandrel 106 and / or receiver 116 to queue the product 118 for detecting of non-conformities. Thereafter, the transfer device 302 may securely collect the product 118 from the mandrel 106 and / or receiver 116 and place the product on a conveyor assembly, a secondary conveyor assembly, a bin, or collection jig 308.

[0033] In some embodiments, the transfer device 302 comprises a suction cup 306. Thesuction cup 306 may be operatively coupled to a pneumatic vacuum circuit. In another embodiment, the suction cup 306 may be operatively coupled to a venturi device structured to receive air from a pressurized pneumatic circuit and output a pneumatic vacuum, wherein the pneumatic vacuum is supplied to the suction cup 306. In either embodiment, the pneumatic circuit may be engaged or disengaged by electronic valves controlled by the controller. In this way, the transfer device 302 is assisted in holding, lifting, and articulating the product 118 with minimal unwanted movement of the product 118.

[0034] Referring back to Figure 2, the apparatus 100 may further contain a controller box 202. Controller 202 may contain at least a portion of the electronics, hardware, controller, and computer instructions required to control, monitor, and operate the apparatus 100. In some embodiments, the controller box 202 is enclosed in an enclosure structure to protect the electronics, hardware, controller, and computer instructions from inadvertent manipulation. Further, in some embodiments the controller box 202 may include a user interface 204 operatively coupled to the controller 430 that provides a graphical display of the imaging device 102 controls, imaging device 102 output, light emitter 114 controls, the statuses of various inputs and outputs, and so forth.

[0035] The controller box 202 also contains a controller 430, one example of which may be a programmable logic controller (“PLC”) as will be described in detail with respect to Figure 4. In some embodiments, the controller box 202 may also contain a pneumatic control system, lighting control system, imaging device control system, and / or a camera control system, each of which is operatively coupled to the controller 430.

[0036] Figure 4 illustrates an exemplary component-level structure of the controller 430, in accordance with an embodiment of the invention. As shown in Figure 4, the controller 430 may include a processor 402, memory 404, input / output (VO) device 416, and a storage device 406. The controller 430 may also include a high-speed interface 408 connecting to the memory 404, and a low-speed interface 412 connecting to low speed bus 414 and storage device 406. Each of the components 402, 404, 408, 110, and 412 may be operatively coupled to one another using various buses and may be mounted on a common motherboard or in other manners as appropriate. As described herein, the processor 402 may include a number of subsystems to execute the portions of processes described herein. Each subsystem may be a self-contained component of a larger system (e.g., controller 430) and capable of being configured to execute specialized processes as part of the larger system.

[0037] The processor 402 can process instructions, such as instructions of an application that may perform the functions disclosed herein. These instructions may be stored in the memory 404 (e.g., non-transitory storage device) or on the storage device 406, for execution within the controller 430 using any subsystems described herein. It is to be understood that the controller 430 may use, as appropriate, multiple processors, along with multiple memories, and / or I / O devices, to execute the processes described herein.

[0038] The memory 404 stores information within the controller 430. In one implementation, the memory 404 is a volatile memory unit or units, such as volatile random access memory (RAM) having a cache area for the temporary storage of information, such as a command, instructions related to various methods and / or functionalities described herein, and / or the like. In another implementation, the memory 404 is a non-volatile memory unit or units. The memory 404 may also be another form of computer-readable medium, such as a magnetic or optical disk, which may be embedded and / or may be removable. The non-volatile memory may additionally or alternatively include an EEPROM, flash memory, and / or the like for storage of information such as instructions and / or data that may be read during execution of computer instructions. The memory 404 may store, recall, receive, transmit, and / or access various files and / or information used by the controller 430 during operation.

[0039] The storage device 406 is capable of providing mass storage for the controller 430. In one aspect, the storage device 406 may be or contain a computer-readable medium, such as a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. A computer program product can be tangibly embodied in an information carrier. The computer program product may also contain instructions that, when executed, perform one or more methods, such as those described above. The information carrier may be a non-transitory computer- or machine-readable storage medium, such as the memory 404, the storage device 406, or memory on processor 402.

[0040] The high-speed interface 408 manages bandwidth-intensive operations for the controller 430, while the low speed controller 412 manages lower bandwidth-intensive operations. Such allocation of functions is exemplary only. In some embodiments, the high-speed interface 408 is coupled to memory 404, input / output (I / O) device 416 (e.g., through a graphics processor or accelerator), and to high-speed expansion ports 411, which may accept various expansion cards(not shown). In such an implementation, low-speed controller 412 is coupled to storage device 406 and low-speed expansion port 414. The low-speed expansion port 414, which may include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet), may be coupled to one or more input / output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.

[0041] The processor 402 may be configured to communicate with the user through a control interface and display interface coupled to a display (not depicted graphically in Figure 4). The display may be, for example, a TFT LCD (Thin-Film-Transistor Liquid Crystal Display) or an OLED (Organic Light Emitting Diode) display, or other appropriate display technology. The display interface may comprise appropriate circuitry and configured for driving the display to present graphical and other information to a user. The control interface may receive commands from a user and convert them for submission to the processor 402. In addition, an external interface may be provided in communication with processor 402, so as to enable near area communication of controller 430 with other devices. The external interface may provide, for example, for wired communication in some implementations, or for wireless communication in other implementations, and multiple interfaces may also be used.

[0042] The controller 430 may be implemented in a number of different forms. For example, it may be implemented as a standard server, or multiple times in a group of such servers. Additionally, the controller 430 may also be implemented as part of a rack server system or a personal computer such as a laptop computer. Alternatively, components from controller 430 may be combined with one or more other same or similar systems and an entire controller 430 may be made up of multiple computing devices communicating with each other.

[0043] Figure 5 illustrates a process flow 500 for detecting non-conformities in products, according to one embodiment of the present invention. The process may begin at block 502, where the system stores a predetermined lux value. The predetermined lux value may be received by the controller from a user through interaction with a user interface in operable communication with the controller. The processor 402 may then execute computer instructions to store the predetermined lux value in storage device 406. The predetermined lux value (e.g., the target lux value) may be set by the user as a result of experimentation, since the ideal lux value(s) for determining non-conformities in products is dependent on a variety of factors, including, but not limited to the shape and size of the product 118, the amount of ambient light, various settings oflight emitter 114, and so forth. A user may provide the apparatus with a sample product containing a known number of non-conformities, choose an arbitrary lux value, subject the sample product to the imaging device 102 of the apparatus, analyze the images of the sample product using the algorithmic image processing methods, and note the percentage of non-conformities that were detected by the algorithmic image processing. If the algorithmic image processing does not detect each of the known number of non-conformities, the user may then select a different predetermined lux value and repeat the experiment. Once the algorithmic imaging processing identifies each of the known non-conformities of the sample product, the user may then use the corresponding predetermined lux value for the quality monitoring of the remainder of the products that are similar to the sample product. However, the ideal lux value is not essential to the operation of the apparatus, as the apparatus is structured to maintain a predetermined lux value, whether the ideal lux value or not.

[0044] In some embodiments, the user may also predetermine (via a user interface) and store in the storage device 406 an acceptability range, such as to account for a mathematical or acceptable experimental error. For example, the user may determine that a lux value within a range of + / - 1 lx of the predetermined lux value is still capable of allowing the algorithmic imaging processing to identify the correct number of non-conformities.

[0045] The process may then continue at block 504, where the controller receives data from a photo sensor representing the lux value of the light energy reflected by the product 118 secured on the mandrel 106. The photo sensor may be a portion of the camera 112 or the imaging device 102.

[0046] The process may then continue at block 506, where the processor 402 of the controller compares the data from the photo sensor (e.g., data representing the lux value of the light energy reflected by the product 118 secured on the mandrel 106, or “measured lux value”) to the predetermined lux value stored in the storage device 102. As one non-limiting example, the predetermined lux value may be stored as 128 lx, while the data from the photo sensor representing the lux value at the point in time at which the photo sensor obtained the lux value may be 125 lx. The processor 402 of the controller would numerically compare the 128 lx of the predetermined lux value to the 125 lx of the measured lux and determine that the two are not identical.

[0047] Accordingly, as illustrated in block 508, the processor 402 may then determine if the measured lux value is within an acceptability limit of the predetermined lux value. Continuingwith the previous example, the processor 402 may apply the + / - 1 lx acceptability range to the predetermined lux value of 128 lx, such that the processor 402 of the controller then determines mathematically if the measured lux value of 125 lx is within the ranges of 127 lx and 129 lx.

[0048] In some embodiments, a predetermined acceptability range may not be defined by the user or otherwise implemented if the user desires for the measured lux value to be identical to the predetermined lux value.

[0049] If the measured lux value is not within the predetermined acceptability range, or if, as in some embodiments, the measured lux value is not identical to the predetermined lux value, the process may continue at block 512, where the controller transmits instructions to the support device 108 to move the camera 112 relative to the mandrel 106. In some embodiments, the controller may be provided with a predetermined movement increment, such as 1mm, 2mm, 5mm, 10mm, 50mm, 100mm, and so forth, or any dimension therebetween. In some embodiments, the controller may provide instruction to the support device 108 to move the support device 108 (and thereby move the camera 112) towards the product 118 by the predetermined movement increment if the measured lux value is below the predetermined lux value. In other embodiments, the controller may provide instruction to the support device 108 to move the support device 108 (and thereby move the camera 112) towards the product 118 by the predetermined movement increment if the measured lux value is above the predetermined lux value. In some embodiments, the direction of movement (e.g., a movement vector) of the support device 108 may be predetermined by a user.

[0050] Thereafter, the process may then continue at block 514, where the controller receives data from the position sensor 115 representing the relative position of the camera 112 to the mandrel 106. As previously described, the imaging device 102 may comprise a position sensor 115. By receiving data from the positioning sensor, the controller is able to confirm the location of the camera 112 relative the mandrel 106, before, during, and / or after each movement of the camera 112 relative the mandrel 106. In this way, the controller may positively confirm that a previous instruction to move the support device 108 resulted in the movement by the predetermined movement increment, and / or predetermined movement vector. Further, by monitoring the position of the camera 112 relative the mandrel 106, the controller may ensure that any portion of the imaging device 102 safely avoids the product 118, mandrel 106, or any other physical object.

[0051] Referring back now to block 508, if the measured lux value is within the predetermined acceptability range, or if, as in some embodiments, the measured lux value is equal to the predetermined lux value, the process may continue at block 510 where the support device 108 is not provided instructions to move the camera 112. In other words, the camera 112 is maintained at the current position. The controller may also be provided with a predetermined time interval (e.g., a sampling rate) by a user to indicate the length of time at which the camera 112 should maintain its position via the support device 108 prior to reverting back to block 504 to receive data from the photo sensor representing the lux value of the light energy reflected by the product 118 on the mandrel 106. Accordingly, a closed-loop system is formed where the process recurs cyclically at each time interval, determining at each increment of the predetermined time interval if the measured lux value is equal to, or within an acceptability range of, the predetermined lux value, and transmitting instructions to move or maintain the position of the camera 112 relative the mandrel 106.

[0052] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

[0053] As will be appreciated by one of ordinary skill in the art in view of this disclosure, the present invention may include and / or be embodied as an apparatus (including, for example, a system, machine, device, computer program product, and / or the like), as a method (including, for example, a computer-implemented process, and / or the like), or as any combination of the foregoing. Accordingly, embodiments of the present invention may take the form of an entirely apparatus embodiment, an entirely software embodiment (including firmware, resident software, micro-code, stored procedures in a database, or the like), an entirely hardware embodiment, or an embodiment combining the apparatus, software, and hardware aspects that may generally be referred to herein as a “system.” Furthermore, embodiments of the present invention may take theform of a computer program product that includes a computer-readable storage medium having one or more computer-executable program code portions stored therein. As used herein, a processor, which may include one or more processors, may be “structured to” or “configured to” perform a certain function in a variety of ways, including, for example, by having one or more general-purpose circuits perform the function by executing one or more computer-executable program code portions embodied in a computer-readable medium, and / or by having one or more application-specific circuits perform the function.

[0054] It will be understood that any suitable computer-readable medium may be utilized. The computer-readable medium may include, but is not limited to, a non-transitory computer- readable medium, such as a tangible electronic, magnetic, optical, electromagnetic, infrared, and / or semiconductor system, device, and / or other apparatus. For example, in some embodiments, the non-transitory computer-readable medium includes a tangible medium such as a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a compact disc read-only memory (CD-ROM), and / or some other tangible optical and / or magnetic storage device. In other embodiments of the present invention, however, the computer-readable medium may be transitory, such as, for example, a propagation signal including computer-executable program code portions embodied therein.

[0055] One or more computer-executable program code portions (e.g., computer instructions) for carrying out operations of the present invention may include object-oriented, scripted, and / or unscripted programming languages, such as, for example, Java, Perl, Smalltalk, C++, SAS, SQL, Python, Objective C, JavaScript, and / or the like. In some embodiments, the one or more computer-executable program code portions for carrying out operations of embodiments of the present invention are written in conventional procedural programming languages, such as the “C” programming languages and / or similar programming languages. The computer program code may alternatively or additionally be written in one or more multi-paradigm programming languages, such as, for example, F#.

[0056] Some embodiments of the present invention are described herein with reference to flowchart illustrations and / or block diagrams of apparatus and / or methods. It will be understood that each block included in the flowchart illustrations and / or block diagrams, and / or combinations of blocks included in the flowchart illustrations and / or block diagrams, may be implemented byone or more computer-executable program code portions. These one or more computer-executable program code portions may be provided to a processor of a general purpose computer, special purpose computer, and / or some other programmable data processing apparatus in order to produce a particular machine, such that the one or more computer-executable program code portions, which execute via the processor of the computer and / or other programmable data processing apparatus, create mechanisms for implementing the steps and / or functions represented by the flowchart s) and / or block diagram block(s).

[0057] The one or more computer-executable program code portions may be stored in a transitory and / or non-transitory computer-readable medium (e.g. a memory) that can direct, instruct, and / or cause a computer and / or other programmable data processing apparatus to function in a particular manner, such that the computer-executable program code portions stored in the computer-readable medium produce an article of manufacture including instruction mechanisms which implement the steps and / or functions specified in the flowchart(s) and / or block diagram block(s).

[0058] The one or more computer-executable program code portions may also be loaded onto a computer, controller, and / or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer and / or other programmable apparatus. In some embodiments, this produces a computer-implemented process such that the one or more computer-executable program code portions which execute on the computer and / or other programmable apparatus provide operational steps to implement the steps specified in the flowchart(s) and / or the functions specified in the block diagram block(s). Alternatively, computer- implemented steps may be combined with, and / or replaced with, operator- and / or human- implemented steps in order to carry out an embodiment of the present invention.

[0059] Although many embodiments of the present invention have just been described above, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and / or operational aspects of any of the embodiments of the present invention described and / or contemplated herein may be included in any of the other embodiments of the present invention described and / or contemplated herein, and / or vice versa. In addition, where possible, any terms expressed in the singular form herein aremeant to also include the plural form and / or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and / or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Like numbers refer to like elements throughout.

[0060] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

Claims

WHAT IS CLAIMED IS:

1. An apparatus for detecting non-conformities in a product, comprising: a mandrel structured to secure the product; a light emitter for radiating light energy, wherein the light emitter is positioned adjacent the mandrel so that the light emitter radiates light energy onto the product secured by the mandrel; an imaging device positioned adjacent the mandrel and structured to acquire an image of the product, the imaging device comprising: a support device; a camera secured to the support device, wherein the support device is structured to move the camera; a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel; a controller, the controller comprising a processor and a non-transitory computer readable storage medium for storing at least one computer instruction, the controller being in operable communication with the support device, camera, and photo sensor and wherein the at least one computer instruction is used to perform the following steps: storing a predetermined lux value; receiving data from photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel; comparing the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmitting instructions to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value.

2. The apparatus of Claim 1, wherein the imaging device further comprises a position sensor structured to determine a relative position of the camera to the mandrel.

3. The apparatus of Claim 2, wherein the controller is further in operable communication with the position sensor, and wherein the at least one computer instruction is used to perform the step of: receiving data from the position sensor representing the relative position of the camera to the mandrel.

4. The apparatus of Claim 1, wherein the support device comprises a transfer device structured to receive the product.

5. The apparatus of Claim 4, wherein the transfer device comprises a suction cup.

6. The apparatus of Claim 1, wherein the mandrel is structured to rotate the product.

7. The apparatus of Claim 1, wherein the at least one computer instruction is further used to perform the following steps: receiving at a recurring predetermined interval additional data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel; comparing at each of the recurring predetermined intervals the data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmitting instructions at each of the recurring predetermined intervals to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value; wherein a distance of the movement of the camera relative to the mandrel is determined based on a difference between the lux value of the light energy reflected by the product secured on the mandrel and the predetermined lux value for the corresponding recurring predetermined interval.

8. A computer program product for detecting non-conformities in a product, the computer program product comprising a controller comprising a non-transitory computer- readable medium comprising at least one computer instruction, the controller being in operable communication with a support device, camera, and photo sensor, and wherein the at least one computer instruction is used to perform the following steps: store a predetermined lux value; receive data from a photo sensor of an imaging device representing a lux value of a light energy reflected by a product secured on a mandrel structured to secure the product from a light emitter; wherein the light emitter is positioned adjacent the mandrel so that the light emitter radiates light energy onto the product secured by the mandrel; wherein the imaging device is positioned adjacent the mandrel and structured to acquire an image of the product; and wherein the imaging device comprises: a support device; a camera secured to the support device, wherein the support device is structured to move the camera; a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel; and a controller, the controller being in operable communication with the support device, camera, and photo sensor; compare the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmit instructions to a support device to move a camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value.

9. The computer program product of Claim 8, wherein the imaging device further comprises a position sensor structured to determine a relative position of the camera to the mandrel.

10. The computer program product of Claim 9, wherein computer instruction is furtherused to perform the following steps: receive data from the position sensor representing the relative position of the camera to the mandrel.

11. The computer program product of Claim 8, wherein the support device comprises a transfer device structured to receive the product.

12. The computer program product of Claim 11, wherein the transfer device comprises a suction cup.

13. The computer program product of Claim 8, wherein the mandrel is structured to rotate the product.

14. The computer program product of Claim 8, wherein the at least one computer instruction is further used to perform the following steps: receive at a recurring predetermined interval additional data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel; compare at each of the recurring predetermined intervals the data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmit instructions at each of the recurring predetermined intervals to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value; wherein a distance of the movement of the camera relative to the mandrel is determined based on a difference between the lux value of the light energy reflected by the product secured on the mandrel and the predetermined lux value for the corresponding recurring predetermined interval.

15. A method for detecting non-conformities in a product comprising: storing a predetermined lux value;receiving data from a photo sensor of an imaging device representing a lux value of a light energy reflected by a product secured on a mandrel from a light emitter for radiating light energy, wherein the light emitter is positioned adjacent the mandrel so that the light emitter radiates light energy onto the product secured by the mandrel; comparing the data from the photo sensor representing the lux value of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmitting instructions to a support device to move a camera relative to a mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value; wherein the mandrel is structured to secure the product; wherein the imaging device is positioned adjacent the mandrel and structured to acquire an image of the product, the imaging device comprising a support device, a camera secured to the support device, and wherein the support device is structured to move the camera, a photo sensor for reading a lux value of the light energy reflected by the product secured on the mandrel.

16. The method of Claim 15, wherein the imaging device further comprises a position sensor and further comprising determining a relative position of the camera to the mandrel using the position sensor.

17. The method of Claim 16 further comprising: receiving data from the position sensor representing the relative position of the camera to the mandrel.

18. The method of Claim 15, wherein the support device comprises a transfer device and further comprising receiving the product by the transfer device.

19. The method of Claim 18, wherein the transfer device comprises a suction cup.

20. The method of Claim 15, further comprising rotating the product with the mandrel.21 . The method of Claim 15, further comprising the following steps: receiving at a recurring predetermined interval additional data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel; comparing at each of the recurring predetermined intervals the data from the photo sensor representing the lux values of the light energy reflected by the product secured on the mandrel to the predetermined lux value; and transmitting instructions at each of the recurring predetermined intervals to the support device to move the camera relative to the mandrel when the lux value of the light energy reflected by the product secured on the mandrel differs from the predetermined lux value; wherein a distance of the movement of the camera relative to the mandrel is determined based on a difference between the lux value of the light energy reflected by the product secured on the mandrel and the predetermined lux value for the corresponding recurring predetermined interval.

Images