Container Sidewall Inspection Optics for Multi-Line Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container inspection devices face challenges in efficiently inspecting the side walls of containers for flaws, foreign substances, or dirt, with issues such as low inspection efficiency, variation in accuracy due to container location, and blurred image data leading to inaccurate determination of defects.
Innovation Solution
A container inspection device employing optical path conversion sheets that convert light paths from the side walls of multiple containers into a unified optical axis, combined with an imaging optical system and hardware processor, allowing simultaneous inspection of multiple containers with high accuracy and precision in defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a wide angle lens is placed immediately above the opening of a container to inspect the side wall portion, then the inspection capability for side walls is enabled, but the number of containers that can be imaged simultaneously is limited to only one
Solution Approach 1:
The patent introduces a second dimension by placing cameras at oblique positions above and below the container opening, rather than only from the top. This spatial arrangement allows multiple containers to be imaged simultaneously in a single frame, transforming a one-dimensional inspection approach into a multi-dimensional one that increases throughput
2Productivity
If a pair of cameras is placed to take images of side wall portions from obliquely above, then simultaneous imaging of multiple containers is enabled, but the size of the side wall portion in the image data varies by container location
Solution Approach 1:
The patent applies local quality by using separate camera pairs positioned at different locations (above and below the container opening) to image different portions of the side walls. Each camera pair is optimized for its specific viewing angle and target region, ensuring consistent image quality and measurement precision across all containers regardless of their position on the conveyor
3Difficulty of detecting and measuring
If a camera is used to take an image of a container via a prism sheet, then the side wall portion can be imaged, but the image data is likely to be blurred
Solution Approach 1:
The patent eliminates the prism sheet intermediary by directly positioning cameras to capture images of the side wall portions. This direct imaging approach removes the optical path that caused blurring, resulting in sharp, clear images that enable accurate detection of defects while maintaining the ability to image multiple containers simultaneously
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 device enables efficient and accurate detection of defects on the entire circumference of container side walls, reducing variation in inspection accuracy and improving the precision of defect localization.
Implementation Method 1
optical path conversion sheets that convert an optical path of the light radiated from the irradiator and reflected from or transmitted through side wall areas that extend in a circumferential direction of side walls of each of the containers
Data Source
AI summary
A container inspection device includes: an irradiator that irradiates, with light, containers transferred in an arrangement of multiple lines; an imaging sensor that images the radiated light; optical path conversion sheets that convert an optical path of the light; an imaging optical system that forms an image of the light along the converted optical path onto the imaging sensor; and a hardware processor that identifies whether the side walls include defective based on image data obtained from the light imaged on the imaging sensor. The optical path conversion sheets are laid across the multiple lines. The optical path conversion sheets respectively correspond to the side wall areas, and each of the optical path conversion sheets converts the optical path of the light reflected from or transmitted through a corresponding one of the side wall areas into an optical path along an optical axis of the imaging optical system.