360-Degree Dense Point Inspection for In-Line CAD-Based Defect Detection
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Solution Overview
Problem
Existing inspection systems require complex setup and are inefficient in obtaining dense sampling of objects, often necessitating manual positioning and sparse measurement points, leading to increased time and cost in verifying conformance to specifications.
Innovation Solution
An automated, in-line quality inspection system using a non-contact optical scanning method with a laser profilometer that scans three-dimensional surface geometry, allowing for real-time comparison with CAD models to detect defects and variations, regardless of object orientation, and capable of inspecting multiple objects simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional CMMs and laser trackers are used for inspection, then measurement precision can be achieved, but setup time and device complexity increase significantly
Solution Approach 1:
The patent replaces traditional mechanical measurement systems (CMMs, laser trackers) with a non-contact optical scanning system that uses light to capture 3D surface geometry. This substitution eliminates the need for mechanical contact and complex positioning mechanisms, thereby reducing setup time while maintaining measurement precision through optical triangulation and phase-shift methods.
Solution Approach 2:
The inspection system is designed to be universal and adaptable to various object types and orientations without requiring custom jigs or positioning fixtures for each part. The system can inspect multiple different parts on the same conveyor belt using the same hardware configuration, significantly reducing setup time compared to dedicated inspection systems.
2Quantity of substance
If traditional inspection systems are used, then sparse sampling of measurements can be obtained, but the complexity of measuring entire objects increases
Solution Approach 1:
The patent replaces point-by-point mechanical probing with continuous optical surface scanning. The optical system captures entire surface profiles simultaneously using line scanners or area scanners, generating dense point clouds that represent the complete object surface rather than sparse discrete points, thereby increasing the quantity of measurement data without proportionally increasing system complexity.
Solution Approach 2:
The system transitions from one-dimensional point measurements to two-dimensional surface profile capture, and ultimately to three-dimensional point cloud reconstruction. This dimensional escalation allows the system to obtain dense sampling across the entire object surface by adding spatial dimensions to the measurement process, capturing X-Y-Z coordinates for numerous points simultaneously rather than sequentially.
3Measurement precision
If non-contact profilometers with relative mechanical movement are used, then 3D point cloud can be generated, but setup complexity and time increase
Solution Approach 1:
The patent eliminates the need for complex mechanical movement systems by using a stationary optical scanner combined with a moving conveyor belt. Instead of mechanically moving the scanner relative to the object, the object moves under the stationary scanner, simplifying the mechanical infrastructure while maintaining the ability to generate 3D point clouds through the relative motion between scanner and object.
Solution Approach 2:
The system creates a digital copy (point cloud) of the physical object's surface geometry without requiring physical contact or complex mechanical manipulation of the object itself. The optical scanner captures light reflected from the object surface to construct a digital 3D representation, simplifying the inspection process by working with digital data rather than physical handling.
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
The system enables efficient, high-precision quality control with reduced setup time and cost, providing real-time defect detection and predictive maintenance by ensuring consistent conformance to specifications across various manufacturing stages.
Implementation Method 1
a non-contact optical scanning method with a laser profilometer that scans three-dimensional surface geometry
Implementation Method 2
non-contact optical scanning method with a laser profilometer that scans three-dimensional surface geometry
Data Source
AI summary
A system and method for performing real-time quality inspection of objects is disclosed. The system and method include a transport to move objects being inspected, allowing the inspection to be performed in-line. At least one optical acquisition unit is provided that captured optical images of the objects being inspected. The captured optical images are matched to CAD models of objects, and the matched CAD model is extracted. A laser with an illumination light beam has a wavelength in the violet or ultraviolet range then conducts scans of the objects, which are formed into three-dimensional point clouds. The point clouds are compared to the extracted CAD models for each object, where CTF are compared to user input or CAD model information and the object is determined to be acceptable or defective based on the extent of deviation between the point cloud and the CAD model.