Curved Object Visual Inspection via Dynamic Exposure Optimization
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Solution Overview
Problem
Conventional visual inspection systems for curved objects face challenges in accurately identifying defects due to varying exposure values across different surfaces, leading to frequent adjustments of camera angles and lighting, which is time-consuming.
Innovation Solution
A visual inspection method utilizing a robotic arm, camera, and control unit that captures object images with preset parameters, calculates better shooting parameters by counting pixels occupied by grayscale values, and adjusts exposure and angles to maximize target grayscale values, enabling batch inspections with reduced re-adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the camera and light source positions are frequently adjusted to achieve correct exposure for each surface of the curved object, then the exposure quality of different surfaces is improved, but the inspection time is significantly increased
Solution Approach 1:
The system performs preliminary actions by capturing multiple object images with different exposure settings before the actual inspection. These preliminary images are used to calculate optimal shooting parameters (including exposure compensation values) in advance, so that during batch inspection, the pre-calculated parameters can be directly applied without frequent adjustments, thus resolving the contradiction between exposure quality and inspection time
Solution Approach 2:
The system changes exposure parameters by capturing images with different exposure settings and calculating exposure compensation values based on grayscale distribution. These parameter changes allow the system to adapt to different surfaces of the curved object while maintaining efficient batch inspection, improving exposure quality without proportionally increasing inspection time
2Reliability
If multiple photographs are taken with different exposure settings to capture all surfaces properly, then the completeness of defect detection is improved, but the complexity of the inspection process increases
Solution Approach 1:
The system creates copies of object images with different exposure settings during the preliminary capture phase. These copied images are then analyzed to determine optimal shooting parameters, which are subsequently applied to all batch inspections. This copying approach ensures complete defect detection across all surfaces while simplifying the actual inspection process by reusing the same optimized parameters
Solution Approach 2:
The system performs the complex multi-exposure photography and parameter calculation as a preliminary action before batch inspection. This one-time preliminary work establishes optimal parameters that can be reused, thereby ensuring defect detection completeness without making the ongoing inspection process complex
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
This approach ensures consistent exposure, reduces re-adjustment times, and enhances the visibility of object features by optimizing exposure and angle settings, thereby improving the efficiency of visual inspections for curved objects.
Implementation Method 1
The normal vector of the object 70 pointing towards the light source, a received light ray and a reflected light ray of a flat part of the object 70 are stronger, and a received light ray and a reflected light ray of an inclined part of the object 70 are weaker.
Data Source
AI summary
A visual inspection method of a curved object executed by a visual inspection system. The visual inspection system includes a robotic arm, a camera mounted at a tail end of the robotic arm, a fixing unit mounted under the camera, and a control unit electrically connected to the robotic arm and the camera. Specific steps of the visual inspection method of the curved object are described hereinafter. Fix a curved object which is to be inspected by the fixing unit. Capture the object which is to be inspected with a plurality of groups of preset parameters by the camera. Use the control unit to calculate a better shooting parameter. Use the better shooting parameter by the camera to proceed with visual inspections of the curved objects which are to be inspected in batches.