Visual inspection system and method

Abstract

A visual inspection system is disclosed that can be used to inspect and identify defects in magnet wire or other objects. The system can include an outer housing, a light source, and at least one visual inspection device. The housing has a channel through which the object to be inspected passes, the channel extending along a longitudinal direction and including an inner surface whose diameter narrows along the longitudinal direction between a first point and an inspection region. The light source can be positioned on the opposite side of the inspection region from the first point along the longitudinal direction. The visual inspection devices can be positioned around the periphery of the inspection region, with each visual inspection device configured to inspect the object through a respective opening in the housing.

Description

[Background technology]

[0001] This application claims priority to U.S. Patent Application No. 18 / 110,409, filed February 16, 2023, the entire contents of which are incorporated herein by reference. [Technical Field]

[0002] Embodiments of the present disclosure relate generally to systems and methods for visual inspection and defect detection of objects, and more particularly to systems and methods for non-contact, in-line visual inspection and defect detection of magnet wire and other objects.

[0003] Visual inspection is utilized to inspect and identify defects in a variety of different objects and products, such as magnet wire and cables. Visual inspection systems and devices typically include one or more cameras configured to inspect the object and compare acquired images and data points to reference values ​​or thresholds to detect or identify defects. It is often desirable to illuminate the object during visual inspection. However, conventional visual inspection systems typically use mirrors to reflect light onto the area where the object is being inspected. Light reflections by mirrors and other conventional techniques often create unwanted glare, which can reduce the accuracy of defect detection. As an example, unwanted glare from a light source can prevent accurate visual detection of insulation defects on magnet wire insulation. Therefore, an opportunity exists for improved systems and methods for visual inspection and defect detection of objects. Additionally, an opportunity exists for improved systems and methods that facilitate non-contact and in-line visual inspection and defect detection of objects.

[0004] The detailed description will be described with reference to the accompanying drawings. In the drawings, the leftmost digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference number in different figures indicates similar or identical items, although various embodiments may utilize elements and / or components other than those shown in the figures. Furthermore, the drawings are provided to illustrate exemplary embodiments described herein and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]

[0005] [Figure 1A] FIG. 1 is a perspective view of an example visual inspection system according to an exemplary embodiment of the present disclosure. [Figure 1B] FIG. 1B is a cross-sectional view of the example visual inspection system of FIG. 1A. [Figure 2A] FIG. 1 is a side view of another example visual inspection system according to an exemplary embodiment of the present disclosure. [Figure 2B] FIG. 2B is an end view of the example system of FIG. 2A. [Figure 2C] FIG. 2B is a cross-sectional view of the example system of FIG. 2A. [Figure 3] 1 is a flowchart illustrating an example of a method for inspecting an object using a non-contact visual inspection system according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0006] Certain embodiments of the present disclosure are directed to systems and apparatus for in-line, non-contact visual inspection of objects to detect defects. In various embodiments, the visual inspection system or apparatus can be utilized in combination with various objects that can be fed or passed longitudinally through the system, such as magnet wire, cable, conduit, tubing, etc. The visual inspection system or apparatus can include an outer housing, at least one light source configured to illuminate an inspection area, and one or more visual inspection devices configured to inspect objects passing through the inspection area. According to one aspect of the present disclosure, the outer housing can include a channel through which the objects to be inspected are passed or fed. The channel can include an inner surface extending along the longitudinal direction and narrowing in diameter along the longitudinal direction between a first point and the inspection area. In certain embodiments, the inner surface of the channel can include a convex surface. Additionally, a light source can be positioned opposite the first point from the inspection area, and the light source can emit light into the channel toward the inspection area. The narrowing diameter of the channel can serve to focus and / or reflect light emitted onto objects in the inspection area, thereby assisting in enhanced inspection by the one or more visual inspection devices. In certain embodiments, the inner surface of the channel may be a diffusing surface that functions to diffuse the light emitted from the light source.

[0007] Various suitable light sources can be utilized in various embodiments of the present disclosure. For example, one or more ring lights can be utilized. In certain embodiments, one or more light-emitting diode ("LED") ring lights can be utilized. Furthermore, in certain embodiments, a single light source (e.g., a ring light, multiple lights positioned closely together, etc.) can be utilized. For example, light can be emitted into the channel from a single longitudinal end of the channel toward the inspection area. In other embodiments, separate light sources (e.g., two separate ring lights, two clusters of lights, etc.) can be utilized. For example, light can be emitted into the channel from both longitudinal ends of the channel toward the inspection area. When two light sources are utilized, the inner surface of the channel can have a shape that narrows in diameter along both longitudinal directions toward the inspection area. For example, a first light source is positioned opposite a first point from the inspection area. The diameter of the inner surface then narrows further between a second point and the inspection area, with the second light source being positioned opposite the second point from the inspection area. In this manner, each light emitted from each light source can be focused and / or reflected by an object within the inspection area. Additionally, the diameter of the channel may narrow at any suitable rate as desired in various embodiments, hi certain embodiments, the diameter may narrow at an angle (or combination of angles) along the length of the channel of between about five degrees (5°) and about sixty-five degrees (65°).

[0008] In various embodiments, various suitable visual inspection devices can be utilized as desired. For example, one or more suitable cameras can be utilized as visual inspection devices. In certain embodiments, multiple cameras can be spaced along the perimeter or edge of the inspection area. Each visual inspection device is configured to inspect or visually inspect objects passing through the inspection area and can detect or facilitate the detection of defects or flaws on the objects (e.g., through software analysis of acquired images or data). In certain embodiments, the number of visual inspection devices utilized can be determined at least in part based on the dimensions of the object being inspected. For example, four cameras can be utilized to inspect an object having a rectangular cross-section.

[0009] The visual inspection system may include various other suitable components, as desired. In certain embodiments, the system may include one or more wire guides (e.g., guide rollers, etc.) configured to position an object for inspection within the inspection region. In certain embodiments, one or more suitable mounting rails may assist in positioning the visual inspection system within a production line to enable in-line inspection and / or defect detection. In certain embodiments, the visual inspection system may include one or more components to prevent objects from damaging the visual inspection device. For example, a quartz tube or other suitable transparent sleeve may be placed within the channel to prevent objects from contacting the visual inspection device. In certain embodiments, the system may also include one or more suitable air ducts or ventilation components to facilitate removal of unwanted foreign objects within the system and / or cooling of internal components.

[0010] Another embodiment of the present disclosure is directed to a method for in-line, non-contact visual inspection of an object, such as a magnet wire, cable, conduit, or tube. A channel may be provided having an inner surface extending along a longitudinal direction and narrowing in diameter along the longitudinal direction between a first point and an inspection region. In certain embodiments, the inner surface of the channel may be a diffusing surface. Light may be emitted into the channel from a light source positioned along the longitudinal direction on the opposite side of the inspection region from the first point. An object to be inspected may be passed through the inspection region, and the object may be inspected by at least one visual inspection device positioned around the periphery of the inspection region. The presence or absence of one or more defects on the object may then be determined based on the inspection by the at least one visual inspection device.

[0011] In various embodiments, various suitable light sources can be used to emit light into the channel as desired. For example, light can be emitted by one or more ring lights, LED ring lights, or other suitable light sources. In certain embodiments, a single light source (e.g., a ring light, multiple lights positioned closely together, etc.) can be used to emit light into the channel from a single longitudinal end of the channel. In other embodiments, separate light sources (e.g., two separate ring lights, two clusters of lights, etc.) can be used. For example, light can be emitted toward the inspection region from both longitudinal ends of the channel. When two light sources are used, the inner surface of the channel can have a shape that narrows in diameter along both longitudinal directions toward the inspection region. For example, a first light source can be positioned opposite a first point from the inspection region. The diameter of the inner surface then narrows further between a second point and the inspection region, and the second light source can be positioned opposite the second point from the inspection region. In this manner, the light emitted from each light source can be focused and / or reflected by objects in the inspection region. Additionally, the diameter of the channel can narrow at various rates as desired in various embodiments, hi certain embodiments, the diameter can narrow at an angle (or combination of angles) along the length of the channel of between about five degrees (5°) and about sixty-five degrees (65°).

[0012] The object can also be inspected by a variety of suitable visual inspection devices. For example, one or more suitable cameras can be utilized as the visual inspection devices. In certain embodiments, multiple cameras can be spaced around the perimeter or edge of the inspection area. Each visual inspection device is configured to inspect or visually inspect objects passing through the inspection area and can detect or facilitate the detection of defects or faults on the object (e.g., through software analysis of acquired images or data).

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The present disclosure will now be described in more detail with reference to the accompanying drawings, in which specific embodiments of the present disclosure are shown. However, the present invention may be embodied in 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 be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Like numbers refer to like elements throughout.

[0014] FIGS. 1A-1B show different views of an exemplary visual inspection system 100 that can be used for in-line, non-contact inspection and defect detection of objects. In particular, FIG. 1A shows a perspective view of the system 100, and FIG. 1B shows a cross-sectional view of the system 100 along a longitudinal direction A-A'. The system 100 includes light sources disposed on either side of an inspection region along the longitudinal direction. The exemplary system 100 will be described in more detail below with reference to FIGS. 1A-1B. FIGS. 2A-2C show different views of another example visual inspection system 200 that can be used for in-line, non-contact inspection and defect detection of objects. In particular, FIG. 2A shows a side view of the system 200, FIG. 2B shows an end view of the system 200, and FIG. 2C shows a cross-sectional view of the system 200 along a longitudinal direction B-B'. The system 200 includes a single light source disposed on one side of an inspection region along the longitudinal direction. The exemplary system 200 will be described in more detail below with reference to FIGS. 2A-2C.

[0015] Visual inspection systems according to embodiments of the present disclosure, such as the exemplary systems 100, 200 shown in FIGS. 1A-2C, can be utilized to examine and / or inspect a variety of suitable types of objects. These objects may include any suitable elongated object that can be fed into the visual inspection system, illuminated, and inspected for defects using a suitable visual inspection device. Examples of suitable objects that can be inspected include, but are not limited to, magnet wire, wire, cable, conduit, pipe, tubing, and the like. In certain embodiments, the visual inspection system can be utilized to inspect and evaluate magnet wire. Additionally, magnet wire may have a variety of suitable cross-sectional shapes, such as circular or rectangular cross-sectional shapes.

[0016] 1A-1B, the system 100 may include a housing 105, one or more light sources 110A, 110B, and one or more visual inspection devices 115A-D. The housing 105 may provide various benefits, including, but not limited to, protecting one or more internal components of the system 100 from physical damage, preventing or limiting damage to one or more internal components from dust or foreign objects, and / or limiting the adverse effects of dust or foreign objects on visual inspection as an object passes through the housing 105. In certain embodiments, the housing 105 may be formed from a single or integral component. If desired, the housing 105 may include one or more access panels or other features that allow access to the internal components of the system 100. In other embodiments, the housing 105 may include multiple components that are selectively attachable or connectable to one another. If desired, the housing 105 may include any suitable number of components connected to one another by suitable attachment means, such as bolts, clips, or the like.

[0017] The housing 105 can be formed from a variety of suitable materials and / or combinations of materials. For example, the housing 105 can be formed from a metallic material (e.g., steel, etc.), a metal alloy, a plastic (e.g., ABS plastic, polycarbonate, etc.), etc. If desired, when the housing includes multiple components, all of the components can be formed from the same material, or at least two components can be formed from different materials. The housing 105 can be formed by a variety of suitable techniques, such as additive manufacturing, casting, molding, etc. In certain embodiments, the housing 105 can be formed by 3D printing or additive manufacturing.

[0018] Housing 105 may also be formed with a variety of suitable dimensions (e.g., length, width, height, cross-sectional area, etc.). In certain embodiments, the dimensions of housing 105 may be based, at least in part, on the size of the object intended to be evaluated with system 100. Using magnet wire as an example object, system 100 may be designed with relatively small dimensions, thereby allowing it to be easily installed in a relatively small space within a magnet wire production line. For example, system 100 may occupy a volume of approximately 3.50 cubic feet or less. Thus, housing 105 may be appropriately sized to fit within the small footprint of overall system 100. In an exemplary embodiment, overall system 100 may have a width of approximately 20.2 inches (513 mm), a longitudinal length of approximately 14.3 inches (363 mm), and a height of approximately 20.2 inches (513 mm). In certain system designs, visual inspection devices 115A-D and corresponding mounting rails 150A-D may extend outwardly and define the width and height dimensions of system 100. In other embodiments, different dimensions may be utilized to accommodate other wire sizes or other objects to be inspected.

[0019] In certain embodiments, one or more suitable components can be utilized to mount or position the system 100 within a manufacturing or production environment, thereby facilitating in-line inspection of objects. As shown in FIGS. 1A and 1B , suitable mounting brackets 120A, 120B can be utilized to position the system 100 within a manufacturing line or other suitable environment. Any number of suitable mounting brackets 120A, 120B can be utilized as desired. In the illustrated embodiment, two mounting brackets 120A, 120B are utilized, and other components of the system 100 can be mounted to the mounting brackets 120A, 120B. For example, the housing 105 and light sources 110A, 110B can be mounted between and to the mounting brackets 120A, 120B. The mounting brackets 120A, 120B can then be utilized to secure the system 100 in an appropriate location or position within the manufacturing environment. For example, each mounting bracket (commonly referred to as mounting bracket 120) can include one or more suitable plates 125A, 125B utilized to mount system 100 to rails or other components within a wireline or other manufacturing environment. System 100 can be oriented in any suitable orientation within the wireline (or other environment), e.g., horizontally or vertically. Any suitable mounting components (e.g., bolts, pins, clips, etc.) can be utilized to secure plates 125A, 125B to mounting brackets 120A, 120B and / or to secure plates 125A, 125B and mounting brackets 120A, 120B to a manufacturing line. Additionally, mounting brackets 120A, 120B and / or plates 125A, 125B can be formed from a variety of suitable materials and / or combinations of materials. For example, mounting brackets 120A, 120B and / or plates 125A, 125B can be formed from a metal material (e.g., steel, etc.), a metal alloy, a plastic (e.g., ABS plastic, polycarbonate, etc.), etc. Additionally, mounting brackets 120A, 120B and plates 125A, 125B can be formed with a variety of suitable dimensions (e.g., length, width, height, cross-sectional area, etc.).Although mounting brackets 120A, 120B are described herein, in other embodiments, various other suitable components, such as mounting rails and / or other mounting mechanisms (e.g., a mounting plate attached to a housing, etc.), can be utilized to secure system 100 within a manufacturing environment. Mounting brackets 120A, 120B are provided by way of example only.

[0020] 1A and 1B, various suitable components can be utilized to mount the housing 105, light sources 110A, 110B, and / or other components of the system 100 to the mounting brackets 120A, 120B. In certain embodiments, one or more light sources 110A, 110B can be mounted directly to their respective mounting brackets 120A, 120B, and the housing 105 can be mounted to the light sources 110A, 110B. In other embodiments, the housing 105 can be mounted to the mounting brackets 120A, 120B, and the light sources can be disposed within the housing 105. In still other embodiments, a combination of mounting the housing 105 and one or more light sources 110A, 110B to the mounting brackets 120A, 120B can be utilized. Additionally, any suitable number of mounting plates, e.g., mounting plates 130A, 130B, can be utilized to mount the light sources 110A, 110B, the housing 105, and / or the mounting brackets 120A, 120B to one another.

[0021] As shown in FIGS. 1A and 1B , the first light source 110A can be mounted to the housing 105 using one or more mounting plates 130A, 130B. In other words, the first light source 110A can be directly mounted to the mounting bracket 120A on one longitudinal side, and then mounted to the housing 105 on the opposite longitudinal side via the mounting plates 130A, 130B. In this manner, the light source 110A can remain stationary while the housing 105 can rotate about a suitable axis, such as the longitudinal axis defined by line A-A′. The first mounting plate 130A is attached to the light source 110A, and the second mounting plate 130B is attached to the housing 105. Alternatively, the housing 105 may include suitable mounting portions or components. In other words, the second mounting plate 130B may be integrated into the housing. The two mounting plates 130A, 130B can be rotatably attached to each other via suitable components, such as a turntable assembly, a rotary bearing, a rotary swivel, or the like. The second light source 110B can be mounted directly on the opposite side of the housing 105 and rotatably mounted to the second mounting bracket 120B via a suitable component (e.g., a rotary bearing, a rotary swivel, a turntable, etc.). In this manner, the second light source 110B can rotate along its longitudinal axis. In other embodiments, both light sources 110A, 120A can be rotatably mounted within the system or can be fixed stationary. Furthermore, the housing 105 can remain stationary or can be configured to rotate along its longitudinal axis. Allowing the housing 105 to rotate can facilitate inspection of an object from any direction or combination of directions.

[0022] When one or more mounting plates 130A, 130B are utilized, each mounting plate (commonly referred to as mounting plate 130) may be formed from any suitable material or combination of materials, such as a metallic material (e.g., steel, etc.), a metal alloy, or a plastic (e.g., ABS plastic, polycarbonate, etc.). Furthermore, each mounting plate 130 may be formed with a variety of suitable dimensions (e.g., length, width, height, cross-sectional area, etc.). Furthermore, in other embodiments, a variety of other suitable mounting mechanisms may be utilized to attach mounting brackets 120A, 120B, light sources 110A, 110B, and housing 105 to one another, as desired.

[0023] 1A and 1B, a channel 135 may extend longitudinally through the housing 105. An object to be inspected by the system 100 may pass through the channel 135. For example, an object may enter the housing 105 at a first longitudinal end of the channel, pass through the channel 135, and exit the housing at the opposite longitudinal end. The channel 135 may be formed with various suitable dimensions as desired in various embodiments. In certain embodiments, the dimensions of the channel 135 may be determined at least in part based on the dimensions of the object to be inspected by the system 100. If desired, corresponding openings aligned with the channel 135 may be formed in other components of the system 100, such as the mounting brackets 120A and 120B. Similarly, the light sources 110A and 110B may be positioned to allow an object to pass through the channel without contacting the light sources 110A and 110B. In certain embodiments, the light sources 110A and 110B are ring lights, and the object may pass through an opening in the center of the ring light.

[0024] Additionally, channel 135 may include an inspection region 140 where objects are evaluated by one or more visual inspection devices 115A-D. In other words, visual inspection devices 115A-D may be positioned within channel 135 at the periphery or periphery of inspection region 140. As objects pass through channel 135, they may be inspected and evaluated by inspection devices 115A-D as they pass through inspection region 140. Inspection region 140 may be positioned at any suitable location along the longitudinal length of channel 135. Furthermore, inspection region 140 may have a variety of suitable dimensions, such as any suitable longitudinal length, diameter, and / or cross-sectional area. In certain embodiments, the dimensions of inspection region 140 may be determined at least in part based on the dimensions of the object to be inspected and / or the dimensions of visual inspection devices 115A-D.

[0025] System 100 may optionally include any number of guides to facilitate maintaining an object in a desired position within housing 105 and / or inspection region 140 for proper evaluation by inspection devices 115A-D. In an exemplary system 100 configured to inspect a wire (e.g., a rectangular magnet wire, etc.), system 100 may include multiple wire guide rollers (not shown), such as a horizontal guide roller positioned at each end of housing 105 and a vertical guide roller positioned at each end of housing 105. In an exemplary embodiment, a first horizontal roller may help maintain the horizontal position of the wire as the wire enters housing 105, and a first vertical roller may help maintain the vertical position of the wire as the wire exits housing 105. Similarly, a second horizontal roller may help maintain the horizontal position of the wire, and a second vertical roller may help maintain the vertical position of the wire as the wire exits housing 105. As a result, the wire may pass through inspection region 140 within a desired or optimal distance (or range of distances) from inspection devices 115A-D. Any suitable type of guide roller can be utilized as desired, such as a roller including a fixed first roller element and a spring-loaded second roller element. Such rollers can be utilized to accommodate different wire sizes. Other suitable types of wire guides (e.g., dies, funnels, etc.) can be utilized in other embodiments and will be understood by those skilled in the art. Additionally, other suitable types of guides can be utilized to inspect other types of objects.

[0026] According to one aspect of the present disclosure, the channel 135 may include an inner surface 145 that functions to focus or reflect light emitted from the light sources 110A, 110B onto objects within the inspection region 140. More specifically, the channel 135 may narrow in diameter (or other suitable cross-sectional area) along the length of the channel 135 between each light source and the inspection region 140. In the exemplary system 100 of FIGS. 1A and 1B, the channel 135 may narrow along the length between a first point and the inspection region 140, with the first light source 110A positioned opposite the first point from the inspection region along the length. Additionally, the channel 135 may narrow along the length between a second point and the inspection region 140, with the second light source 110B positioned opposite the second point from the inspection region along the length. In an appearance inspection system including a single light source, such as the exemplary system 200 of Figures 2A-2C described in detail below, the channel may simply narrow between the first point and the inspection area, with the light source positioned opposite the first point.

[0027] In certain embodiments, the inner surface 145 of the channel 135 can be narrowed to facilitate focusing and / or reflecting light emitted from the light sources 110A, 110B onto objects within the inspection region 140. In certain embodiments, the light can be reflected off the objects and directed toward the visual inspection devices 115A-D. Focusing and reflecting light by the inner surface 145 can result in significantly less glare than conventional inspection systems that utilize mirrors to focus light. As desired, the degree of narrowing can be determined based at least in part on various suitable factors, such as the dimensions of the light sources 110A, 110B (e.g., the diameter of a ring light, etc.), the maximum diameter size of the channel 135 (e.g., the maximum diameter corresponding to the dimensions of the light sources 110A, 110B, etc.), the desired diameter or diameter range of the channel within the inspection region 140, and / or the minimum diameter size required to facilitate passage of objects through the channel 135. The inner surface 145 can narrow in diameter (or cross-sectional area) at any suitable rate (i.e., narrow along its length in the region between the light source and the inspection region 140). In certain embodiments, the diameter can narrow along its length at an angle (or combination of angles) of between about five degrees (5°) and about sixty-five degrees (65°). In various embodiments, the diameter can narrow at an angle of about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, or 65 degrees, or an angle within a range between any two of the foregoing values. It will further be understood that the angle of narrowing can vary or vary over the longitudinal length of the channel 135. For example, in a section of the channel having a convex shape, the angle of narrowing can vary parabolically.

[0028] Additionally, in certain embodiments, the diameter of the inner surface 145 can narrow according to various suitable geometric shapes. For example, in certain embodiments, the diameter of the inner surface 145 can narrow convexly between the light source 110 and the inspection region 140. In other words, the inner surface 145 can have a convex shape. It has been found that an inner surface 145 having a convex shape optimally focuses light onto the inspection region 140. In other embodiments, the diameter of the inner surface 145 can narrow parabolically. In yet other embodiments, the diameter of the inner surface 145 can narrow in a linear slope. Other suitable shapes or narrowing rates can be utilized in other embodiments, so long as the emitted light is sufficiently focused onto objects within the inspection region 140.

[0029] In certain embodiments, the inner surface 145 of the channel 130 can continue to narrow within the inspection region 140 or within a desired portion of the inspection region 140. For example, if a single light source is used, the inner surface 145 can narrow along the entire length of the inspection region 140 or a desired longitudinal portion thereof. As another example, if two light sources 110A, 110B are used, the inner surface 145 can narrow from a first point along the longitudinal length of the channel 135 (i.e., a first point disposed between the first light source 110A and the inspection region 140) to the inspection region 140, and in some embodiments, along a desired portion of the inspection region 140. Similarly, the inner surface 145 can narrow from a second point along the longitudinal length of the channel 135 (i.e., a second point disposed between the second light source 110B and the inspection region 140) to the inspection region 140, and in some embodiments, along a desired portion of the inspection region 140. In other words, along its length, the inner surface 145 may narrow in diameter between the first light source 110A and the inspection region 140, and then begin to widen or expand toward the second light source 110B. In certain embodiments, substantially all of the longitudinal length of the inner surface 145 through the inspection region 140 may include some percentage narrowing or widening in diameter (e.g., the inner surface 145 is convex through the inspection region 140). In other embodiments, at least a portion along the longitudinal length of the inspection region 140 may have a relatively constant diameter (or cross-sectional area).

[0030] If desired, the inner surface 145 (or any desired portion of the inner surface 145) can incorporate a diffusing surface or material to further promote scattering, diffuse reflection, or spreading of light within the channel 135. Diffusing light emitted toward the inspection region 140 has been found to improve the ability of a visual inspection device to evaluate an object. If desired, various suitable diffusing materials can be utilized to allow the inner surface 145 to function as a diffusing surface. For example, the inner surface 145 can be coated with a diffusing material, such as white paint, other diffusing paints, chalk, clay, or the like. Additionally, in certain embodiments, the inner surface 145 can be roughened or include a rough finish to promote scattering.

[0031] 1A and 1B, one or more light sources 110A, 110B can be incorporated into the system 100. Any number of light sources can be utilized. Furthermore, various suitable types of light sources can be utilized. As shown, each ring light 110A, 110B is positioned on either longitudinal side of the housing 105, with each ring light 110A, 110B configured to emit light into the channel 135 and toward the inspection area 140. The ring light advantageously allows an object to pass through the central opening and the channel 135. Various suitable ring lights can be utilized in various embodiments as desired. In certain embodiments, LED ring lights can be utilized. Each ring light can have an inner diameter selected to function according to the size of the object being inspected and an outer diameter selected to emit a desired amount of light. In certain embodiments, a CA-DRM5X ring light sold by Keyence Corporation can be utilized. Other suitable ring lights can be utilized in other embodiments. In still other embodiments, multiple LED lights may be positioned at desired locations (e.g., at spaced locations around the perimeter or edge) such that the multiple lights radiate a desired amount of light into channel 135. In other embodiments, a variety of other suitable lighting configurations may be utilized.

[0032] As shown in FIGS. 1A and 1B, certain embodiments may utilize two light sources. As described in more detail below with reference to FIGS. 2A-2C, other embodiments may utilize a single light source. In certain conventional visual inspection devices, a ring light may be positioned around each visual inspection device. For example, a ring light may be positioned around each camera lens used in the conventional device. A system incorporating four cameras would utilize four ring lights or other light sources. Therefore, embodiments of the present disclosure may utilize fewer light sources than conventional devices while incorporating the same or similar number of cameras or other visual inspection devices. Therefore, the systems of the present disclosure may operate more efficiently.

[0033] As desired, each light source (generally referred to as light source 110) may remain stationary or may be allowed to rotate, spin, or otherwise move. As shown in Figures 1A and 1B, a first light source 110A may remain stationary and a second light source 110B may rotate with the housing 105. In other embodiments, other configurations of stationary and / or rotating light sources may be utilized.

[0034] 1A and 1B, system 100 can include one or more visual inspection devices 115A-D. Each visual inspection device (commonly referred to as visual inspection device 115) can non-contactly and in-line evaluate an object passing through inspection region 140 to detect or identify defects or faults on the object's surface. For example, a visual inspection device can inspect or visually inspect an object and evaluate acquired images or data using one or more appropriate algorithms or software (e.g., software running on the visual inspection device, software running on one or more computer devices in communication with the visual inspection device, etc.) to identify defects or faults on the object. For example, as magnet wire is manufactured and an insulation coating is formed, one or more visual inspection devices 115A-D can inspect the surface of the wire's insulation coating and determine whether defects, beads, or other faults are present using an appropriate algorithm. Appropriate focusing and / or diffusion of light within inspection region 140 can facilitate improved or enhanced detection by visual inspection devices 115A-D compared to conventional devices.

[0035] Any number of suitable visual inspection devices can be incorporated into system 100 as desired. As shown, four visual inspection devices 115A-D can be utilized. The illustrated system 100 is intended for use in inspecting objects having a rectangular cross-sectional shape (e.g., rectangular magnet wire, etc.). Thus, four visual inspection devices 115A-D can be used to inspect each side of the object. Other suitable numbers of visual inspection devices 115A-D can be utilized in combination with objects having other suitable cross-sectional shapes (e.g., circular, oval, hexagonal, etc.). In other words, the number of visual inspection devices can be determined, at least in part, based on the dimensions of the object being inspected. In various embodiments, system 100 can include one, two, three, four, five, six, eight, ten, or any other desired number of visual inspection devices. Additionally, in certain embodiments, housing 105 can be rotated to rotate or adjust the position of visual inspection devices 115A-D and / or the angle at which the object is inspected.

[0036] Various suitable types of visual inspection devices 115A-D may be utilized as desired in various embodiments. For example, one or more suitable cameras may be utilized as the visual inspection devices 115A-D. Other suitable visual inspection devices may include any suitable device configured to acquire images of an object for evaluation. In certain embodiments, as illustrated, multiple visual inspection devices 115A-D may be spaced apart along the perimeter or peripheral edge of the inspection area 140. Any suitable spacing may be utilized between adjacent inspection devices 115A-D. For example, four visual inspection devices 115A-D may be spaced apart at approximately 90 degrees from one another.

[0037] Each visual inspection device 115 can be mounted to other components of the system 100 using a variety of suitable mounting mechanisms and / or techniques. As shown, multiple mounting rails 150A-D extend from the housing 105, and each visual inspection device 115A-D can be mounted to a corresponding mounting rail 150A-D. The mounting rails 150A-D can be used to adjust the position of the visual inspection devices 115A-D (e.g., along the length of the rail), to accommodate visual inspection devices of various sizes, and / or to facilitate easy removal, maintenance, and / or replacement of the visual inspection devices 115A-D. In other embodiments, the visual inspection devices 115A-D can be mounted directly to the exterior of the housing 105 (e.g., with bolts, pins, etc.), to the housing 105 using other suitable components, or to components of the system 100 other than the housing 105. Additionally, mounting rails 150A-D may be formed in any suitable dimension or from any suitable material or combination of materials, such as a metallic material (e.g., steel, etc.), a metal alloy, a plastic (e.g., ABS resin, polycarbonate, etc.), etc.

[0038] Openings or slots 155A-D can be formed through the housing 105 to allow the visual inspection devices 115A-D to evaluate objects. For example, each visual inspection device 115A-D can have a respective opening 155A-D formed through the housing 105. If desired, a cap can be placed over the lens of each visual inspection device 115A-D, and the cap can include a slot or opening that serves to focus and narrow the area of ​​the object being inspected. If desired, a filter can also be used, in addition or instead. In operation, each visual inspection device 115 can acquire images or other data from the object through the corresponding opening or slot (and slot or filter in the cap) and evaluate the acquired images / data.

[0039] In certain embodiments, system 100 may further include one or more components to protect visual inspection devices 115A-D and / or other sensitive components of system 100 from damage caused by objects passing through system 100 and / or from damage during initial feeding of the objects into system 100. Various suitable protective components may be used as desired. For example, in certain embodiments, a transparent protective sleeve 160 may be disposed within channel 135 between the object and visual inspection devices 115A-D and / or inner surface 145. The transparent sleeve 160 may be formed from various suitable materials. For example, in certain embodiments, a quartz tube may be used as the protective sleeve 160. Furthermore, the transparent sleeve may be formed in various suitable dimensions, including any suitable thickness. In other embodiments, a removable sleeve may be disposed within channel 135 to facilitate initial feeding of the object into system 100. The sleeve may then be removed before the object passes through system 100 for inspection. Suitable guides (e.g., wire rollers, etc.) may maintain the position of the object within channel 135 during operation. In yet other embodiments, removable or selectively openable caps may be utilized to protect the visual inspection devices 115A-D when objects are initially fed into the system 100. In yet other embodiments, transparent protective covers or caps may be placed over the lenses of the visual inspection devices 115A-D. Various other suitable protective components may be used in other embodiments as desired.

[0040] In certain embodiments, system 100 may optionally include one or more air ducts to facilitate the supply or input of pressurized air into housing 105 via a suitable ventilation system or air supply (not shown). The pressurized air may assist in removing and / or preventing the intrusion of foreign matter within housing 105. As a result, the internal components of system 100 (e.g., visual inspection devices 115A-D, etc.) may be maintained in better operating condition and kept clean. Additionally, the pressurized air may assist in cooling one or more internal components of system 100, such as internal computing devices (e.g., circuit boards, electronic boards, microcontrollers, etc.).

[0041] System 100 may include any suitable number of computing devices for controlling the operation of system 100. Various suitable computing devices, such as circuit boards, programmable logic arrays, microcontrollers, minicomputers, etc., may be utilized as desired. Alternatively, system 100 may be controlled by one or more external computing devices in communication with various components of system 100. The computing devices may perform various suitable operations, such as, but not limited to, providing control signals to visual inspection devices 115A-D, processing and evaluating images and / or data received from visual inspection devices 115A-D, identifying or determining the presence or absence of defects on inspected objects, counting defects, calculating defect sizes, generating appropriate warning or output signals, and / or communicating with any suitable number of external devices or systems, as desired. In an exemplary embodiment, the computing devices may be configured to receive various signals or data, such as a line speed input, one or more thresholds or criteria (e.g., defect amplitude threshold, defect count threshold, etc.), one or more reset signals, etc. Based on its calculations and processing, the computing device may be configured to output any number of suitable signals, such as one or more identified defect counts (e.g., counts for different defect sizes), defect amplitudes, longitudinal lengths of the defects, identification of the visual inspection device 115A-D that identified the defects, a handshake signal, etc. The computing system may also be configured to store various suitable data, such as defect count data.

[0042] System 100 can provide various benefits or advantages over conventional visual inspection systems or devices. First, focusing, reflecting, and / or diffusing light onto objects in the inspection area allows for more accurate detection of defects through visual inspection. Many conventional systems incorporate mirrors to focus or reflect light, but these mirrors can cause glare that reduces the performance of the visual inspection device. Additionally, the present system can utilize fewer light sources than conventional systems with the same number of visual inspection devices, resulting in greater efficiency, lower cost, and smaller overall size.

[0043] In operation, system 100 can evaluate or inspect an object in a non-contact and non-destructive manner. System 100 can also operate in-line, for example, while an object is being manufactured or produced. Furthermore, system 100 can provide real-time feedback when defects or failures are identified.

[0044] In other embodiments, system 100 can include various other components as desired. For example, system 100 can include any suitable object guide (e.g., a wire guide, etc.), attachments, and / or a computing device (or controller). As another example, system 100 can be capable of wired and / or wireless communication with external systems or devices. It will be understood that the disclosed embodiments may include more or fewer components than those described and illustrated above with reference to FIGS. 1A-1B. Indeed, the illustrated system 100 is provided only as a limiting example.

[0045] 2A-2C, another exemplary system 200 for facilitating visual inspection of an object is shown. In particular, FIG. 2A illustrates a side view of exemplary system 200, FIG. 2B illustrates an end view of system 200, and FIG. 2C illustrates a cross-sectional view of system 200 along a longitudinal direction B-B'. System 200 may include components similar to those of system 100 of FIGS. 1A-1B. For example, system 200 may include a housing 205, a light source 210, and one or more visual inspection devices 215A-D. However, in contrast to system 100 of FIGS. 1A-1B, system 200 may include a single light source 210 rather than two light sources.

[0046] The housing 205 can be formed from materials similar to those described above with reference to FIGS. 1A-1B. Furthermore, the housing 205 can be formed in a variety of suitable dimensions. In certain embodiments, the housing 205 can be formed with smaller dimensions than the housing 105 of FIGS. 1A-1B because only a single light source 210 is used (assuming the light source is of comparable size). As shown, the housing 205 and light source 210 can optionally rest or be placed within a suitable cradle 220 or stand structure. The cradle 220 allows the housing 205 to rotate therein. If desired, any suitable mounting components (e.g., bolts, pins, etc.) can be utilized to secure the housing 205 in a desired position during operation of the system 200. The cradle 220 can include any suitable number of legs or rails mountable within a production line or environment, and the cradle 220 can include extensions or arms that allow the housing 205 to be secured in place. Instead of utilizing the illustrated cradle 220, any suitable number of mounting brackets or other components may be utilized to secure the housing 205 and / or the entire system 200 within a production environment.

[0047] 1A-1B, an object to be inspected can pass through the channel 235 and be inspected by the visual inspection devices 215A-D in an appropriate inspection region 240. Furthermore, the channel 235 can have an inner surface 245 that narrows in diameter longitudinally between the light source 210 and the inspection region 240 (or between longitudinal points located between the light source 210 and the inspection region 240). The narrowing of the channel 235 can focus and / or reflect light emitted by the light source 210 onto the object in the inspection region 240, thereby enabling the desired visual inspection by the inspection devices 215A-D.

[0048] 1A-1B, the inner surface 245 can have a diameter (or cross-sectional area) that narrows at any suitable rate and / or any suitable geometric shape. For example, in certain embodiments, the diameter of the inner surface 245 can narrow convexly between the light source 210 and the inspection region 240. In other words, the inner surface 245 can have a convex shape. In other embodiments, the diameter of the inner surface 245 can narrow parabolically. In still other embodiments, the diameter of the inner surface 245 can narrow at a linear gradient or a constant rate. Other suitable shapes or narrowing rates can be utilized in other embodiments as desired, so long as the light emitted onto the object in the inspection region 240 is sufficiently focused.

[0049] Additionally, the inner surface (of system 100 of FIGS. 1A-1B or system 200 of FIGS. 2A-2C) can include any suitable combination of narrowing shapes. For example, a first longitudinally extending portion can narrow convexly, and a second longitudinally extending portion can narrow in diameter in a linear gradient. FIG. 2C illustrates an exemplary inner surface 245 including a first convexly narrowing portion (e.g., between the light source 210 and the beginning of the inspection region 240) and a second linearly narrowing portion (e.g., extending past the inspection region 240 and beyond). Furthermore, in certain embodiments, the system's inner surface 245 can continue to narrow from the light source 210 to the opposite side of the inspection region 240. With only a single light source 210, the inner surface 245 need not widen toward the second light source. Furthermore, the continuing narrowing can reflect emitted light that passes through the inspection region 240 back into the inspection region 240, thereby compensating for the absence of light from the second light source. Additionally, in certain embodiments, the inner surface 245 can include or be formed from a diffusing material, similar to that described above for the system 100 of FIGS. 1A-1B.

[0050] Continuing with reference to FIGS. 2A-2C, the light source 210 and visual inspection devices 215A-D can be similar to those described above for the system of FIGS. 1A-1D. Any suitable number of visual inspection devices 215A-D can be utilized as desired. Furthermore, various suitable types of visual inspection devices 215A-D, such as suitable cameras, can be utilized. As shown in FIGS. 2A-2C, the visual inspection devices 215A-D can be secured to the cradle 220 via any suitable number of mounting brackets 250A-D, such as a respective mounting bracket 250A-D for each corresponding inspection device. Alternatively, the visual inspection devices 215A-D can be mounted to the housing 205 via any suitable mounting brackets and / or rails. Indeed, the mounting techniques illustrated in FIGS. 2A-2C are provided by way of limited example only. Additionally, one or more openings 225A-D or slots can be formed through the housing 205 to allow the visual inspection devices 215A-D to inspect objects within the inspection region 240. These openings may be similar to those described above for system 100 of Figures 1A-1B.

[0051] System 200 may optionally include various other components in other embodiments. For example, system 200 may include one or more transparent protective sleeves (e.g., quartz tubes, etc.), one or more suitable object guides (e.g., wire guides, etc.), any suitable mounting components, one or more suitable ventilation components, and / or any suitable number of computing devices (or controllers). These components may be similar to those described above with reference to FIGS. 1A-1B. If desired, system 200 may be capable of wired and / or wireless communication with external systems or devices. It will be understood that embodiments of the present disclosure may include more or fewer components than those described above with reference to FIGS. 2A-2C. Indeed, the illustrated system 200 is provided by way of limited example only.

[0052] FIG. 3 is a flowchart illustrating an exemplary method 300 for inspecting an object with a visual inspection system, according to an exemplary embodiment of the present disclosure. Method 300 can be performed by or utilized in conjunction with various visual inspection systems, such as the exemplary systems 100 and 200 shown in FIGS. 1A-2C and described in detail above. Method 300 can begin at block 305, where a suitable visual inspection system can be provided. For example, in block 305, a longitudinally extending channel through which an object can pass is provided. The channel can include an inner surface whose diameter (or cross-sectional area) narrows as it extends from a light source toward an inspection region. For example, if a single light source is utilized, the inner surface can narrow from a first point along the longitudinal direction (e.g., a first point located between the light source and the inspection region) toward the inspection region. As another example, if two light sources are utilized and positioned at opposite longitudinal ends of the channel, the inner surface can narrow from a first point along the longitudinal direction (e.g., a first point located between the first light source and the inspection region) toward the inspection region. The inner surface can further narrow along the longitudinal direction from a second point (e.g., a second point located between the second light source and the inspection area) toward the inspection area. The inner surface can narrow at a suitable rate to facilitate focusing light emitted from the one or more light sources onto objects within the inspection area. If desired, the inner surface can narrow according to various suitable geometric shapes or combinations of shapes, such as convex, parabolic, and / or linear shapes. Furthermore, in certain embodiments, the inner surface can constitute a diffusing surface.

[0053] In block 310, one or more suitable visual inspection devices (e.g., cameras, etc.) can be positioned around the perimeter or periphery of the inspection area. The visual inspection devices are configured to capture images and / or data as the object passes through the inspection area, and the captured images and / or data can be evaluated and / or otherwise processed to determine whether defects or imperfections exist on the object. The visual inspection devices can be positioned at various suitable locations around the inspection area. For example, if four visual inspection devices are utilized, the devices can be positioned approximately 90 degrees apart from each other.

[0054] At block 315, light can be emitted into the channel by one or more suitable light sources. In certain embodiments, a single light source can be positioned near one longitudinal end of the channel and emit light into the channel. In other embodiments, a light source can be positioned near each longitudinal end and each light source can emit light into the channel. A variety of suitable light sources can be used to emit light into the channel, such as an LED ring light.

[0055] In block 320, an object may be passed through the channel and the inspection region. For example, the object may be passed through the channel as it is manufactured or produced in a suitable manufacturing environment. In block 325, the object may be inspected by one or more visual inspection devices while it is in the inspection region. For example, the object may be inspected continuously in an in-line manner as it passes through the inspection region. In block 330, it may be determined whether a defect or fault is identified or detected on the object. For example, images and / or data acquired by the visual inspection devices may be evaluated and / or analyzed (e.g., compared to reference data or threshold data) to determine whether a defect or fault is present. If it is determined in block 330 that no defect is present, the operation may return to block 325, and inspection may continue as the object passes through the inspection region.

[0056] However, if block 330 determines that one or more defects are present on the object, operations may proceed to block 335. At block 335, various appropriate actions may be taken based on the identification or detection of the defects or failures. For example, an alert may be generated. As another example, a defect counter may be incremented for each identified defect, and an alert may be issued if a threshold counter (i.e., a threshold counter associated with a minimum number of allowable defects) is determined to have been exceeded. As yet another example, the amplitude or magnitude of the defects may be determined, and an alert may be issued if the defect size is determined to have exceeded one or more thresholds. Additionally, as desired, certain embodiments may determine whether manufacturing or production of the object wire should be stopped (e.g., based on a determined defect size or the number of defects detected). If it is determined that production should not be stopped, operations may return to block 325 and continue monitoring the object. However, if it is determined that production should be stopped, operations may proceed to block 335 and output an appropriate stop command or alert. Method 300 may end after block 335 or when the visual inspection device is powered off.

[0057] If desired, method 300 may include more or fewer operations than those depicted in Figure 3. Furthermore, if desired, certain operations of method 300 may be performed in a different order than that depicted in Figure 3, or in parallel. Indeed, method 300 is provided only as a limiting example.

[0058] Conditional language, such as "can," "can," "might," or "potential," among others, is generally intended to indicate that certain embodiments include certain features, elements, and / or operations, and other embodiments do not, unless expressly stated otherwise or understood otherwise by the context in which it is used. Thus, such conditional language is not intended to imply that features, elements, and / or operations are in any way required in one or more embodiments, or that one or more embodiments necessarily include logic for determining whether to include or perform these features, elements, and / or operations in a particular embodiment, with or without user input or prompting.

[0059] Many modifications and other embodiments of the disclosure set forth herein will be apparent to those having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is therefore to be understood that the disclosure is not limited to the particular embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. an outer housing including a channel through which an object to be inspected passes, the channel having an inner surface extending along a longitudinal direction and narrowing in diameter along the longitudinal direction between a first point and the inspection region; a light source disposed on an opposite side of the first point from the inspection area along the longitudinal direction; At least one visual inspection device arranged on the outer periphery of the inspection area; Including, each visual inspection device configured to inspect the object through a respective opening in the exterior housing; Visual inspection system.

2. The system of claim 1 , wherein the light source comprises a ring light.

3. The system of claim 1 , wherein the inner surface comprises a convex inner surface.

4. 2. The system of claim 1, wherein the diameter of the inner surface further narrows along the longitudinal direction between a second point and the inspection area, the second point being located on an opposite side of the inspection area from the first point along the longitudinal direction, and the light source comprises a first light source; The system further includes a second light source positioned along the longitudinal direction on an opposite side of the inspection area from the second point.

5. The system of claim 1 , wherein the diameter of the inner surface narrows at an angle between 5 degrees and 65 degrees between the first point and the inspection region.

6. The system of claim 1 , wherein the at least one visual inspection device includes a camera.

7. The system of claim 1 , wherein the at least one visual inspection device includes a plurality of cameras spaced along a perimeter of the inspection area.

8. The system of claim 1 , wherein the inner surface of the channel has a diffusing surface that diffuses light emitted from the light source.

9. The system of claim 1 , further comprising a transparent sleeve disposed within the channel.

10. The system of claim 9 , wherein the transparent sleeve comprises a quartz tube.

11. The system of claim 1 , wherein the object comprises a magnet wire.

12. an outer housing including a channel through which an object to be inspected passes, the channel having an inner surface extending along a longitudinal direction and narrowing in diameter from opposite ends toward an inspection region located between the opposite ends; a light source disposed near each end of the channel; At least one visual inspection device arranged on the outer periphery of the inspection area; Including, each visual inspection device configured to inspect the object through a respective opening in the exterior housing; Visual inspection system.

13. The system of claim 12 , wherein the light sources each comprise a ring light.

14. The system of claim 12 , wherein the inner surface comprises a convex inner surface.

15. 13. The system of claim 12, wherein the diameter of the inner surface narrows at an angle between 5 degrees and 65 degrees between at least one end and the inspection region.

16. The system of claim 12 , wherein the at least one visual inspection device includes a camera.

17. The system of claim 12 , wherein the at least one visual inspection device includes a plurality of cameras spaced along a perimeter of the inspection area.

18. The system of claim 12 , wherein the inner surface of the channel has a diffusing surface that diffuses the light emitted from each light source.

19. The system of claim 12 further comprising a transparent sleeve disposed within the channel.

20. 20. The system of claim 19, wherein the transparent sleeve comprises a quartz tube.

21. The system of claim 12 , wherein the object comprises a magnet wire.

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