Ceramic Ball Surface Defect Inspection With Multi-Angle Imaging
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Solution Overview
Problem
Existing methods for inspecting surface defects in ceramic sintered bodies with a band-shaped portion around a spherical surface portion suffer from low precision due to shadow casting and fluctuating light conditions, particularly when ball size changes, leading to inefficiencies and human error in defect detection.
Innovation Solution
A method involving a surface defect inspection device that rotates the ceramic sintered body on an arrangement member with spherical members, photographs from multiple directions using a line sensor, and detects defects through image analysis, enabling precise detection of defects on the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual observation by person is used for surface defect inspection, then inspection can be performed, but human errors occur and yield rate is influenced
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an automated optical inspection system using a camera, illumination device, and image processing unit. This substitution eliminates human errors and ensures consistent inspection quality across all ceramic sintered bodies.
Solution Approach 2:
The patent introduces an intermediary image processing system that captures images of the ceramic sintered body and automatically analyzes them for defects. This intermediary system acts as a mediator between the object being inspected and the final defect detection result, removing direct human involvement from the inspection process.
2Measurement precision
If reflected light inspection method is used, then inspection can be performed, but band-shaped portion casts shadow and accurate inspection cannot be performed
Solution Approach 1:
The patent applies local quality by using multiple illumination devices positioned at different locations to illuminate different regions of the ceramic sintered body. This ensures that the band-shaped portion and other surface features are properly lit from multiple angles, preventing shadow formation and enabling accurate defect detection across the entire surface.
Solution Approach 2:
The patent transitions from a single-point or single-direction illumination approach to multi-dimensional illumination by positioning illumination devices at multiple locations around the ceramic sintered body. This multi-dimensional lighting approach eliminates shadows cast by the band-shaped portion and enables comprehensive surface inspection.
3Adaptability or versatility
If reflected light inspection is used, then inspection can be performed, but when ball size changes contrast of reflected light changes and inspection precision lowers
Solution Approach 1:
The patent creates a universal inspection system that can handle ceramic sintered bodies of various sizes by using multiple illumination devices and a camera positioned to capture the entire surface. The system adapts to different ball sizes through automated image processing that normalizes the captured images, maintaining consistent inspection precision across different dimensions.
Solution Approach 2:
The patent employs parameter changes in the image processing stage to compensate for variations in ball size. The system captures images at different scales and uses processing algorithms to normalize the images to a standard reference size, allowing consistent defect detection regardless of the original ceramic sintered body dimensions.
4Measurement precision
If image inspection in oil is used, then inspection precision can be maintained when ball size changes, but it is difficult to stabilize image quality due to fluctuation of oil
Solution Approach 1:
The patent extracts the inspection process from the problematic oil environment by using dry illumination and imaging. The system captures images of the ceramic sintered body in air using controlled lighting, eliminating the oil medium that causes fluctuations and image quality instability while maintaining inspection precision through digital image processing.
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 method achieves high precision in defect detection, allowing for efficient identification of defects as small as 0.5 mm, reduces human error, and enhances yield rates by improving the accuracy of ceramic ball production.
Implementation Method 1
an inspection about a defect is performed by using a contrast pattern of reflected light
Data Source
AI summary
A surface defect inspection method for a ceramic sintered body including a spherical surface portion according to an embodiment includes: an arrangement step; a photographing control step; and a detection step. The arrangement step arranges the ceramic sintered body on an arrangement member having a plurality of spherical members. The photographing control step rotates the ceramic sintered body arranged on the arrangement member in response to rotation of the plurality of spherical members, photographs the ceramic sintered body, which is arranged on the arrangement member, from a plurality of directions, and acquires a plurality of images. The detection step detects a surface defect of the ceramic sintered body based on the plurality of images.