Composite Inspection Light Arrays for Wide Material Defect Detection
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Solution Overview
Problem
Current automated material placement inspection systems are ineffective for materials wider than six inches, as they struggle to provide reliable defect detection across broader widths.
Innovation Solution
A method and apparatus utilizing a combination of light and laser sources to illuminate and inspect materials, with cameras capturing images for defect detection, allowing for scalable inspection systems that can handle varying material widths by projecting light and laser energy normal to the material and using reflective surfaces to ensure even illumination and reveal imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current automated visual inspection systems are used, then inspection can be performed during material laying, but they are ineffective for materials wider than six inches
Solution Approach 1:
The inspection system divides the wide material into multiple inspection zones by using multiple light sources and cameras arranged in arrays. Each light source-camera pair inspects a specific section, and the sections are combined to form a complete inspection of the entire wide material width, enabling effective inspection beyond the six-inch limitation of single-unit systems
Solution Approach 2:
The inspection system is designed to be universally applicable to materials of varying widths by using configurable arrays of light sources and cameras. The system can adapt to different material widths by adjusting the number and arrangement of inspection units, making it versatile for both narrow and wide materials while maintaining inspection effectiveness
2Measurement precision
If light is projected at an angle to reveal imperfections, then defects can be detected, but illumination may not be even across wide materials
Solution Approach 1:
The system employs multiple light sources positioned at different locations, each projecting light at optimized angles for its specific inspection zone. This allows each local area to have tailored illumination quality that reveals imperfections effectively, while the collective arrangement ensures even illumination across the entire wide material surface
Solution Approach 2:
The system combines multiple angled light projections from different light sources into a unified illumination pattern. By merging these individual angled illuminations, the system achieves both the defect-revealing angular illumination and the even coverage necessary for wide materials
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
Enables effective inspection of wider materials by providing even illumination and enhanced defect detection, including fuzz balls, resin balls, and backing materials, improving upon existing systems by allowing for broader coverage without significant machine downtime.
Implementation Method 1
Light is projected onto the material in a direction normal to the material to illuminate the material
Implementation Method 2
Laser energy is projected onto the material at an angle predetermined to reveal imperfections in the material
Implementation Method 3
projecting laser energy onto the material at an angle predetermined to reveal imperfections in the material
Data Source
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AI summary
A system and method of inspecting material laid by a material placement machine. Light is directed onto the material in a direction essentially normal to the material to illuminate a section of the material. Laser energy is projected onto the section at an angle predetermined to reveal imperfections in the section. This system provides improved illumination for material widths exceeding six inches and is scalable for inspecting various material widths.