Auto Focus Module for Vision Inspection Systems
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Solution Overview
Problem
Conventional vision inspection systems are labor-intensive and costly, with low detection accuracy due to human error and variability in image quality affected by the imaging device's distance from the parts, leading to inconsistent product quality.
Innovation Solution
A vision inspection system with an auto focus module that determines the optimal working distance for the imaging device by calculating image contrast scores at different distances, ensuring high-quality images and reducing human error through automated adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used, then labor cost is high and detection accuracy is low, but the system is simple to implement
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated vision inspection system using imaging devices, processors, and algorithms. The system captures images of parts, processes them through contrast calculation and analysis algorithms, and automatically detects defects without human intervention, thereby eliminating human error while maintaining system implementability.
2Manufacturing precision
If the imaging device distance from parts is not optimized, then image quality is inconsistent, but adjusting the distance manually is time-consuming
Solution Approach 1:
The patent implements an autofocus mechanism that automatically adjusts the imaging device distance from parts. The system calculates image contrast at different distances, identifies the optimal distance that maximizes contrast, and automatically positions the imaging device accordingly. This self-adjusting capability eliminates manual intervention, ensures consistent image quality, and reduces the time required for distance optimization.
3Reliability
If automated vision inspection is implemented, then detection accuracy improves, but the cost of the system increases
Solution Approach 1:
The patent optimizes system cost by dynamically adjusting key parameters including imaging device distance, exposure time, and gain settings based on real-time image contrast analysis. By adapting these parameters to match the specific inspection requirements and part characteristics, the system achieves high detection accuracy and product consistency while avoiding the need for expensive fixed-configuration hardware, thereby reducing overall system cost.
Data Source
AI summary
A vision inspection system includes a platform supporting parts for inspection at an inspection zone, an inspection station positioned adjacent the platform at the inspection zone including an imaging device to image the parts in a field of view above the upper surface, and a vision inspection controller receiving images from the imaging device. The vision inspection controller includes an auto focus module for orienting the imaging device relative to the inspection zone. The auto focus module determines a working distance for the imaging device from the inspection zone. The auto focus module calculates an image contrast score of pixel values of the images at various working distances from the inspection zone. The vision inspection controller causes the inspection station to operate the imaging device at an imaging working distance corresponding to the working distance associated with the highest image contrast score.