Camera Calibration System for Sheet Processing Quality Control

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Solution Overview

Problem

The calibration of cameras in quality control stations for sheet element processing machines is burdensome, requiring the machine to be stopped and calibration marks to be placed in the viewing area, which can lead to inefficiencies and errors in quality assessment.

Innovation Solution

A camera calibration system with a target holder and drive that allows for easy placement of an optical target within the camera's viewing area without interrupting the machine's operation, using a pneumatic or hydraulic rod and carrier arm to position the target holder across the width of the quality control station, enabling calibration at different points without modifying the machine setup.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the machine is stopped for camera calibration, then the camera can be calibrated properly, but the productivity of the sheet element processing machine decreases

Engineering Contradiction:

Improvecamera calibration accuracyVSAvoidmachine operation efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The optical target is pre-positioned in the target holder, which is kept ready in the viewing area. The target holder remains positioned in advance, so when calibration is needed, the target is already in place and the machine can continue running without stopping for setup.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The target holder acts as an intermediary device that carries the optical target into the viewing area. It can be quickly inserted or removed from the viewing area without requiring machine shutdown, serving as a mediator between the calibration needs and continuous production.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the entire machine is stopped for calibration, then the camera calibration can be performed, but the loss of time increases

Engineering Contradiction:

Improvecamera calibration accuracyVSAvoidcalibration downtime

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The target holder is pre-positioned in the viewing area before calibration is needed. This preliminary positioning eliminates the time required to set up the calibration target during the calibration process, allowing for rapid calibration without machine shutdown.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The target holder is designed to be dynamically insertable and removable from the viewing area. This dynamic capability allows the calibration target to be quickly introduced when needed and removed when not needed, minimizing the time the machine must be stopped for calibration.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If the optical target is manually placed in the viewing area, then the camera can be calibrated, but the ease of operation decreases

Engineering Contradiction:

Improvecamera calibration accuracyVSAvoidcalibration process simplicity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The target holder serves as an intermediary that simplifies the calibration operation. Instead of manually positioning the optical target itself, the operator simply needs to insert or remove the target holder, which automatically positions the target correctly in the viewing area.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The target holder is a universal component that can be quickly inserted and removed multiple times without requiring different setup procedures. This multi-use design makes the calibration process simple and repeatable, improving ease of operation for successive calibrations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates quick and efficient camera calibration with minimal disruption to the machine's operation, allowing for precise calibration of camera parameters like color, focus, and geometry, reducing the risk of incorrect quality assessments.

Implementation Method 1

a drive for the target holder, the drive being configured for displacing the target holder between a rest position in which it is outside of the viewing area of the camera and a calibration position in which it is arranged in the viewing area of the camera

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Implementation Method 2

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS11117778B2Quality control station with camera calibration system for sheet element processing machine

Publication Date: 2021.09.14 BOBST MEX SA

AI summary

A quality control station (2) for a sheet element processing machine, the station having at least one camera (6) arranged for capturing images of sheet elements (4) transported through the quality control station (2), and further having a camera calibration system (10). The camera calibration system (10) having a target holder (12) for holding an optical target (14), and a drive (15) for the target holder (12). The drive (15) is adapted for displacing the target holder (12) between a rest position, in which it is outside of the viewing area (7) of the camera (6), and a calibration position in which it is arranged in the viewing area (7) of the camera (6).