Cylindrical Beam Splitter for Uniform Camera Inspection Lighting
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Solution Overview
Problem
Conventional camera-based inspection systems require manual adjustment of lighting for different verification methods, making it cumbersome to achieve optimal lighting conditions for parts with varying geometry and finish, especially for Direct Part Marking technologies like Data Matrix, where contrast between marked symbols and backgrounds can be low.
Innovation Solution
A lighting system that automatically and programmatically controls multiple low-angle lights and diffuse illumination sources, using a cylindrical beam splitter to create a seamless illumination effect, allowing for various lighting techniques to be combined into a single system, thereby optimizing lighting for camera-based inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple separate lighting systems are used for different verification methods, then lighting optimization for specific applications is achieved, but system complexity and manual adjustment requirements increase
Solution Approach 1:
The patent combines multiple separate lighting systems into a single integrated lighting system that can provide different lighting conditions (diffuse lighting, directional lighting, low angle lighting) through one unified structure. This merging approach maintains the ability to optimize lighting for different verification methods while reducing system complexity and eliminating manual adjustment requirements.
Solution Approach 2:
The integrated lighting system is designed to perform multiple functions simultaneously - it can provide diffuse lighting, directional lighting, and low angle lighting all through one system. This multi-functionality allows the system to adapt to different verification methods and application requirements without requiring separate dedicated lighting systems for each function.
2Illumination intensity
If manual adjustment of lighting is required for different verification methods, then lighting can be optimized for each method, but ease of operation deteriorates
Solution Approach 1:
The lighting system incorporates programmable control that automatically selects and adjusts the appropriate lighting conditions based on the verification method being used. The system serves itself by making lighting adjustments without requiring manual intervention, thereby maintaining lighting optimization while significantly improving ease of operation.
Solution Approach 2:
The lighting system is designed to be dynamically adjustable through programmable control, allowing it to automatically transition between different lighting modes (diffuse, directional, low angle) based on the verification requirements. This dynamic capability eliminates manual adjustment while preserving the ability to optimize lighting for each specific verification method.
3Device complexity
If conventional lighting systems are used for Direct Part Marking verification, then simple system structure is maintained, but measurement precision of mark readability deteriorates
Solution Approach 1:
The lighting system provides different lighting conditions targeted at specific areas and angles appropriate for Direct Part Marking verification. By implementing local quality variations in the lighting (diffuse lighting for general illumination, directional lighting for specific angle requirements, low angle lighting for surface mark enhancement), the system achieves high measurement precision for mark readability while maintaining a unified structure that doesn't significantly increase overall device complexity.
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 efficient selection of optimal lighting conditions for camera-based inspections, improving the uniformity of illumination and reducing the need for manual adjustments, ensuring compliance with specifications like those set by the AIM TSC and enhancing the readability of marks on parts with diverse surfaces.
Implementation Method 1
reflecting incident light striking from any of a first set of predefined directions and to substantially transparently convey through said beam splitter and to a camera lens incident light traveling in any of a second set of predefined directions
Data Source
AI summary
Certain exemplary embodiments can provide a method comprising: from an angled first end region of a substantially cylindrical beam splitter, reflecting incident light striking from any of a first set of predefined directions and to substantially transparently convey through said beam splitter and to a camera lens incident light traveling in any of a second set of predefined directions, the beam splitter defining a longitudinal central axis.