Curved Surface Imaging via Multi-Camera Composite Vision
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Solution Overview
Problem
Conventional machine vision systems face limitations in throughput due to the time required to mechanically orient objects with curved surfaces for inspection, which hampers their ability to keep up with high-speed production lines.
Innovation Solution
A system comprising a conveyor, sensors, and multiple cameras arranged to capture images from different angles, with a processing device generating a composite 360° image by manipulating and combining images from each camera, allowing for efficient inspection of objects with curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical stops or orientation devices are used to position and orient products, then measurement precision is improved, but productivity deteriorates due to time required to mechanically orient each product
Solution Approach 1:
The patent replaces mechanical orientation devices with an optical imaging system that captures images from multiple fixed cameras simultaneously. The system uses image processing algorithms to determine object orientation and position without mechanical intervention, thereby eliminating the time-consuming mechanical orientation step while maintaining precise measurement capabilities.
Solution Approach 2:
The system performs preliminary capture of images from multiple angles simultaneously as objects pass through the inspection zone. By pre-capturing images from all cameras before mechanical orientation would be required, the system eliminates the need for sequential mechanical positioning and enables parallel processing of orientation and inspection tasks.
2Productivity
If multiple cameras are used to capture images from different angles, then productivity is improved through parallel imaging, but device complexity increases
Solution Approach 1:
The inspection system is segmented into multiple independent camera units, each capturing images from its specific angle. Each camera operates independently with its own image processing pipeline, allowing parallel processing of inspection tasks. This segmentation enables the system to handle multiple objects simultaneously while distributing computational complexity across independent modules.
Solution Approach 2:
The multiple cameras serve universal purposes: they not only capture images for inspection but also provide data for determining object position, orientation, and geometry. The same imaging data is used for multiple functions including defect detection, quality control, and positioning algorithms, thereby reducing the need for separate specialized devices.
Data Source
AI summary
A system for capturing a composite image of an object with a curved surface includes a conveyor configured to transport the object to be imaged to a predetermined imaging position. A sensor is configured to produce a signal when the object to be imaged is at the predetermined position, and several cameras are arranged to photograph the object at the predetermined position from a plurality of different angles. A tracking module is used to receive the signal from the sensor, and output an actuating signal to the several cameras, such that each camera captures an image when the actuating signal is received. A processing device receives a captured image from each of the several cameras, manipulates the received images, and generates a composite image based on the manipulated images.