3D Inspection Using Multi-Axis Image Sensors
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Solution Overview
Problem
Conventional three-dimensional inspection methods for electric components, such as soldered states on electronic boards, rely on human visual inspection, leading to inconsistent quality and low productivity due to the complexity and time required for inspecting intricate components.
Innovation Solution
An apparatus and method utilizing multiple image sensors positioned along non-parallel axes to capture images, analyzing these images to generate directional stereo information, which improves the accuracy and efficiency of three-dimensional inspections by reconstructing the object's appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human inspectors use naked eyes to inspect three-dimensional objects, then inspection can be performed with simple equipment, but inspection quality is inconsistent and productivity is low
Solution Approach 1:
The patent replaces the human visual inspection system with an automated optical inspection system using multiple image sensors. The system captures images from multiple directions (front, rear, left, right, top, bottom) and processes them through a controller to detect defects, thereby eliminating subjectivity and inconsistency of human inspection while significantly increasing productivity.
Solution Approach 2:
The patent transitions from two-dimensional image capture to three-dimensional inspection by arranging image sensors in multiple spatial dimensions. The sensors are positioned to capture images from six different directions, creating a comprehensive 3D view of the object that enables accurate defect detection while maintaining high inspection speed.
2Measurement precision
If multiple image sensors are arranged along non-parallel axes to capture images, then three-dimensional reconstruction accuracy is improved, but device complexity increases
Solution Approach 1:
The patent employs image sensors arranged along three mutually perpendicular axes (x, y, z), capturing images from six different directions. This three-dimensional sensor arrangement enables accurate reconstruction of the object's appearance from multiple viewpoints, significantly improving measurement precision while the systematic orthogonal arrangement keeps the complexity manageable.
Solution Approach 2:
The patent uses a single controller to process images from all six image sensors, making the controller a multi-functional component that handles image acquisition, processing, and three-dimensional reconstruction. This universal approach reduces overall system complexity despite the multiple sensors involved.
3Measurement precision
If conventional single-direction inspection methods are used, then device complexity is low, but inspection accuracy for complex components is insufficient
Solution Approach 1:
The patent transitions from single-direction to multi-directional inspection by positioning image sensors along three mutually perpendicular axes. This three-dimensional arrangement allows the system to capture images from front, rear, left, right, top, and bottom directions, providing comprehensive coverage of complex components and significantly improving inspection accuracy.
Solution Approach 2:
The patent divides the inspection task into six separate image capture operations, each performed by a sensor positioned at a different direction. The controller then integrates these segmented views to create a complete three-dimensional inspection result, improving accuracy for complex components while keeping each individual sensor relatively simple.
Data Source
AI summary
An apparatus for three-dimensional inspection includes a carrier, an image sensing component, and a processor. The carrier is configured to hold an object. The image sensing component is configured to capture a first image, a second image and a third image of the object along a first axis, a second axis, and a third axis respectively, and the first axis, the second axis, and the third axis are not parallel with each other. The processor is configured to analyze the first image and the second image to obtain a first directional stereo information, and analyze the third image and a determined image of the object to obtain a second directional stereo information.