Cylindrical Beam Splitter for Automated Inspection Lighting
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Solution Overview
Problem
Conventional camera-based inspection systems require manual adjustment of lighting settings for different verification methods, which can be cumbersome and inefficient, especially when dealing with varying geometries and finishes of parts.
Innovation Solution
A lighting system that automatically and programmatically controls multiple lighting sources, including bright field and low-angle lights, to provide a range of lighting options, such as diffuse, directional, and low-angle illumination, using a cylindrical beam splitter to eliminate shadows and artifacts, thereby facilitating seamless image capture across various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate lighting systems are used for different verification methods, then lighting options and versatility are improved, but device complexity and manual operation burden increase
Solution Approach 1:
The patent combines multiple separate lighting systems (diffuse lighting, directional lighting, low-angle lighting) into a single integrated illumination device. This merging allows the system to provide diverse lighting options while reducing the number of separate components the user must manually swap, thereby maintaining versatility while reducing operational complexity.
Solution Approach 2:
The illumination device is designed to perform multiple lighting functions simultaneously or selectively. A single device can provide diffuse illumination, directional illumination, and low-angle illumination by activating different light sources or adjusting different optical elements, making the system universal and eliminating the need for multiple specialized lighting devices.
2Ease of manufacture
If manual lighting adjustment is used for different verification methods, then ease of manufacture is improved, but productivity and inspection efficiency decrease
Solution Approach 1:
The system incorporates dynamic control capabilities where lighting parameters can be automatically adjusted based on the inspection requirements. The controller can programmatically change lighting conditions without manual intervention, enabling rapid switching between different verification methods and significantly improving inspection throughput and productivity.
Solution Approach 2:
The illumination device maintains continuous operational readiness by having all lighting modes available simultaneously within a single device. The controller can instantly switch between different lighting configurations without requiring physical changes or setup time, ensuring continuous productive action during inspections.
3Device complexity
If conventional lighting is used for curved or reflective surfaces, then device complexity is reduced, but measurement precision and marking readability decrease
Solution Approach 1:
The system employs different lighting strategies for different regions or types of surfaces. For curved surfaces, low-angle lighting can be selectively activated to enhance contrast. For reflective surfaces, diffuse lighting can be used to minimize glare. This localized application of appropriate lighting quality ensures optimal marking readability for each surface type without requiring complex manual configuration.
Solution Approach 2:
The illumination device can dynamically change lighting parameters such as angle, intensity, and distribution to match the specific surface characteristics being inspected. By programmatically adjusting these parameters, the system optimizes marking visibility for curved or reflective surfaces while maintaining operational simplicity through automated control.
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 and automated selection of optimal lighting conditions for camera-based inspections, ensuring compliance with specifications like AIM's Technical Symbology Committee requirements and enhancing the readability of markings on diverse substrates, including cylindrical and mirror surfaces.
Implementation Method 1
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
Implementation Method 2
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.