Automated Cosmetic Grading via 3D Defect Characterization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for detecting and analyzing surface defects in products lack accuracy and depth measurement, making it difficult to determine the optimal disposition path for items with cosmetic defects, especially in two and three dimensions.
Innovation Solution
A system comprising a camera assembly, lighting assembly, and image processing software that captures comprehensive images, aligns defects with an optical sensor for depth measurement, and applies cosmetic grading schemes to determine the optimal disposition path for items based on defect characterization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used, then the inspection process is simple, but the accuracy and speed of defect detection are insufficient
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system comprising a camera assembly, lighting assembly, and image processing software. This substitution eliminates human subjectivity and fatigue, providing consistent, accurate defect detection while maintaining operational simplicity through automated processing.
Solution Approach 2:
The system creates a digital copy of the object's surface through high-resolution imaging. The camera assembly captures detailed images that are then processed to generate a virtual representation of surface defects, allowing for precise measurement and analysis without physically contacting or altering the actual object.
2Loss of information
If traditional visual inspection is used, then the inspection method is simple, but the depth measurement of defects cannot be obtained
Solution Approach 1:
The patent transitions from two-dimensional visual inspection to three-dimensional defect characterization by incorporating depth measurement capabilities. The optical sensor measures the reflected light intensity at different depths, constructing a vertical dimension of defect information that complements the horizontal surface mapping, enabling full 3D defect profiling.
Solution Approach 2:
The patent introduces light as an intermediary medium to probe defect depth. By analyzing the reflected light intensity at various depths and using this information to calculate defect characteristics, the system indirectly measures depth without requiring physical contact or complex mechanical probing mechanisms.
3Reliability
If comprehensive defect characterization is implemented, then the optimal disposition path can be determined, but the inspection time and processing complexity increase
Solution Approach 1:
The system performs preliminary capture of comprehensive defect information during a single inspection pass. The camera assembly captures multiple images from different angles and the optical sensor measures depth information for all defects simultaneously, storing this data for later analysis. This preliminary data collection eliminates the need for multiple inspection passes, reducing total inspection time while maintaining comprehensive characterization.
Solution Approach 2:
The inspection system operates continuously by capturing images and measuring defect parameters in an uninterrupted sequence. The camera assembly and optical sensor work in tandem to continuously gather defect information as objects move through the inspection area, maintaining constant data acquisition without stopping or repositioning, thereby maximizing inspection efficiency.
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 provides accurate two-dimensional and three-dimensional defect characterization, enabling precise cosmetic grading and optimal disposition decisions, improving efficiency and accuracy over traditional methods.
Implementation Method 1
aligns the defect at a position of highest reflected light intensities and measures the depth at that location
Data Source
AI summary
A system and method for inspection and cosmetic grading of objects is provided. Camera and lighting assemblies capture images of an object and create a 2D composite image which is processed by an image processing module with a deep learning machine algorithm to detect surface defects in the object. Detected defects are localized and measured for depth of defect by an advanced optical sensor, providing a 3D representation of defects. A cosmetic grading algorithm determines the cosmetic grade of the object and the optimal path of disposition for the item based on the grade.