3D Inspection Device Using Dual Light Angles to Eliminate Dead Angles
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Solution Overview
Problem
Existing three-dimensional image inspection devices face challenges with dead angles and low reliability due to issues like multiple light reflections and specular reflections, leading to inaccurate data and reduced inspection accuracy.
Innovation Solution
A three-dimensional image inspection device that uses dual light projecting/receiving parts with different incident and reflection angles to generate and compose three-dimensional data, allowing for selection between reliability priority and measurement priority modes to address dead angles and noise, and incorporates noise removal and dead angle processing to enhance inspection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single light projecting/receiving part is used for three-dimensional measurement, then the device structure is simple, but dead angle regions exist where measurement is disabled
Solution Approach 1:
The measurement system is divided into multiple light projecting/receiving parts, each responsible for measuring specific regions. The first light projecting/receiving part measures regions visible from its position, while the second light projecting/receiving part measures dead angle regions, collectively achieving complete coverage without requiring each component to be overly complex
Solution Approach 2:
The solution transitions from a single measurement viewpoint to multiple viewpoints by adding another light projecting/receiving part positioned at a different spatial location. This dimensional change in measurement perspective eliminates dead angle regions while maintaining reasonable device complexity
2Reliability
If multiple light projecting/receiving parts are used to eliminate dead angles, then measurement coverage is improved, but the device structure becomes more complex
Solution Approach 1:
Multiple light projecting/receiving parts are merged into a coordinated measurement system where each part contributes to the overall three-dimensional data. The composition processing unit integrates measurements from both parts, achieving complete coverage while managing structural complexity through systematic integration
Solution Approach 2:
Each light projecting/receiving part is designed to perform multiple functions: measuring different surface regions, providing redundant measurements for reliability, and contributing to both height information and reflected light intensity data, thereby reducing the need for additional specialized components
3Reliability
If three-dimensional data from both light projecting/receiving parts is used for all pixels, then measurement coverage is maximized, but measurement reliability decreases due to noise from multiple reflections and specular reflections
Solution Approach 1:
Different composition modes are applied to different pixel regions based on local measurement quality. For pixels where both parts provide reliable measurements, both data sources are utilized. For pixels affected by multiple reflections or specular reflections, only the cleaner measurement from the appropriate light projecting/receiving part is used, ensuring local optimization of measurement accuracy
Solution Approach 2:
The system selectively applies measurements from one or both light projecting/receiving parts rather than always using all available data. By partially using measurements only when they meet quality criteria, the system avoids the excessive action of incorporating noisy data from multiple reflections and specular reflections
4Measurement precision
If only reliable three-dimensional data is used for composition, then measurement accuracy is improved, but dead angle regions remain unmeasured
Solution Approach 1:
The system converts the potential harm of noisy measurements from multiple reflections and specular reflections into benefit by using them to fill dead angle regions. While these measurements may be less reliable, they provide valuable coverage in regions that would otherwise be completely unmeasured, and the composition processing selectively utilizes them where appropriate
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device effectively reduces dead angles and improves measurement reliability by prioritizing reliable data and complementing incomplete measurements, resulting in enhanced inspection accuracy and reliability.
Implementation Method 1
generate first three-dimensional data, based on first light receiving amount data obtained from the first light projecting/receiving part, and generate second three-dimensional data, based on second light receiving amount data obtained from the second light projecting/receiving part in accordance with a principle of triangulation
Data Source
AI summary
The three-dimensional image inspection device includes a composed image generation part configured to compose first three-dimensional data and second three-dimensional data, and generate a three-dimensional composed image having information in a height direction, a composition mode selection part configured to enable a first composition mode and a second composition mode to be selected, the first composition mode being a mode in which the three-dimensional composed image is generated, based on the three-dimensional data measured by both a first light projecting/receiving part and a second light projecting/receiving part with respect to respective pixels configuring the three-dimensional composed image, and the second composition mode being a mode in which the three-dimensional composed image is generated, based on the three-dimensional data measured by any one or both of the first light projecting/receiving part and the second light projecting/receiving part with respect to the respective pixels.