Camera-Based Machine Surface Defect Detection
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Solution Overview
Problem
Impurities in manufacturing equipment and production environments cause defects and degrade the performance of endless sheets used in electrochemical cells and capacitors, leading to equipment damage and increased risk of product failure.
Innovation Solution
A system comprising at least one camera and a processing device configured to detect defects in machine surfaces by analyzing image input from the camera, which can be optical and have a resolution of at least 0.5 mm, and output reports or signals on defect presence and location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impurities are present in manufacturing equipment or production environment, then defects are caused and equipment performance is degraded, but detection capability is insufficient to identify and locate these defects
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system consisting of cameras and processing devices. The system captures images of machine surfaces and analyzes them to detect defects such as impurities, scratches, and surface irregularities, thereby eliminating the difficulty of manual detection while maintaining high reliability in defect identification.
Solution Approach 2:
The patent creates optical copies (images) of the machine surfaces using cameras. These digital representations allow for detailed analysis of defects without physical contact with the equipment, enabling reliable detection of impurities and surface defects while preserving the original equipment's operational integrity.
2Manufacturing precision
If surface indents are present on equipment rollers, then dimensional specifications of formed sheets are compromised, but detection and measurement of these indents remains difficult
Solution Approach 1:
The patent employs optical imaging systems to detect surface indents on equipment rollers. The cameras capture high-resolution images of the roller surfaces, and processing devices analyze these images to identify dimensional deviations and surface defects, thereby maintaining manufacturing precision while eliminating the difficulty of manual measurement.
Solution Approach 2:
The patent introduces digital images as an intermediary between the physical roller surfaces and the detection process. These intermediate representations allow for precise measurement and analysis of surface indents without direct physical contact, enabling accurate detection of dimensional specifications while avoiding the complexity of direct mechanical measurement.
3Reliability
If impurities become embedded within endless sheets, then electrochemical cell performance is reduced, but detection of these embedded impurities is challenging
Solution Approach 1:
The patent creates optical copies of the endless sheets during the manufacturing process. These digital images allow for the detection of embedded impurities and defects before they are fully processed into the final product, thereby maintaining electrochemical cell performance while simplifying the detection of hidden contaminants that would otherwise be difficult to identify.
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 system effectively detects and locates defects in machine surfaces, improving the integrity and performance of electrochemical cell production by reducing the risk of product failure and equipment damage.
Implementation Method 1
at least one camera configured to capture image input
Data Source
AI summary
Systems and methods for identifying defects in manufacturing equipment are described. Camera-based image analysis can be used to improve product quality and reliability. Imagery of a machine surface can be repeatedly captured and analyzed by a processing device. Machine surfaces can be etched with landmarks to aid in removing distortion in imagery collected from the surfaces.