Defect Inspection Apparatus with Adjustable Feature Ranges

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Solution Overview

Problem

Current defect inspection methods for industrial products, such as pipelines, are inefficient and reliant on interpreter experience, as they lack precision in detecting various defects like stains, cracks, and chipping, and existing GUIs primarily focus on image quality improvement rather than defect detection precision.

Innovation Solution

A defect inspection apparatus and method that includes image obtaining, processing, and display means to calculate and highlight defect positions and features, allowing for adjustable feature ranges and inspection area specification, along with a user interface for refining defect detection through sliders and inspection history-based criteria.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If exhaustive manual inspection of all defects is performed, then detection precision is improved, but inspection time increases significantly

Engineering Contradiction:

Improvedefect detection precisionVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent segments the inspection process into two phases: automated image processing that identifies all potential defects, and selective manual interpretation that focuses only on suspicious areas. This segmentation allows the system to maintain high detection precision while reducing the time-consuming exhaustive manual inspection of all defects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary automated processing of the entire image to pre-identify all potential defect locations and characteristics before the interpreter begins manual inspection. This preliminary action filters and prioritizes defects, allowing the interpreter to focus only on suspicious areas rather than examining every pixel manually.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If automatic defect detection is implemented, then inspection efficiency is improved, but detection precision deteriorates due to reliance on interpreter experience

Engineering Contradiction:

Improveinspection efficiencyVSAvoiddefect detection precision

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent introduces an automated image processing system as an intermediary between the raw inspection image and the human interpreter. This intermediary performs preliminary defect identification and highlights suspicious areas, serving as a bridge that enhances the interpreter's ability to detect defects accurately while maintaining high inspection efficiency. The system does not replace the interpreter but augments their capabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If all detected defects are displayed, then completeness of inspection is improved, but difficulty in identifying significant defects increases

Engineering Contradiction:

Improvenumber of defects detectedVSAvoiddifficulty in identifying significant defects

Core Design Contradiction:

Quantity of substanceVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies local quality by displaying different visual information for different types of defects based on their characteristics and significance. The system highlights suspicious areas with enhanced visual cues while displaying confirmed defects with distinct markers, allowing the interpreter to quickly identify which defects require immediate attention versus those that are less significant.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system uses color changes and visual highlighting to differentiate between various types of defects and their significance levels. Suspicious areas are highlighted with specific visual indicators, while confirmed defects are marked differently, enabling the interpreter to rapidly assess the importance of each defect without being overwhelmed by the total number of detections.

Inventive Principle:

Principle #32Color changes

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

Enhances precision and efficiency in defect detection by allowing interpreters to focus on specific defect features and areas, reducing reliance on experience and improving the ability to identify subtle defects.

Implementation Method 1

a received-light image created on the basis of reflected light or transmitted light from a test object, the reflected light or the transmitted light being obtained as a result of irradiation of the test object with light rays or radiation rays

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

Methodology Applied

Scientific EffectTransmission:

Data Source

PatentUS10571404B2Defect inspection apparatus, method, and program

Publication Date: 2020.02.25 FUJIFILM CORP

AI summary

To test object image data IMG1, images (possible-defect images D1 to D3) representing possible defects detected by an image processing unit 22 are added. Adjacent to sliders L1 and L2, a histogram H1 indicating the number of detected possible defects for each wall thickness and a histogram H2 indicating the number of detected possible defects for each size are displayed, respectively. When a checkbox CB1 corresponding to a type of defect is selected by an operation unit 14, only images of possible defects of the selected type are displayed on the test object image IMG1. When the sliders L1 and L2 are operated by the operation unit 14, only images of possible defects within a wall thickness range selected by the slider L1 and within a size range selected by the slider L2 are displayed, and images of possible defects outside the ranges are erased.