Diffusion Member for High-Contrast Nozzle Part Inspection
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Solution Overview
Problem
Conventional attraction state inspection devices face challenges in achieving high contrast ratios for images of parts attracted by nozzles, leading to decreased recognition accuracy due to light interference from LEDs, which can increase device size and cost when attempting to resolve these issues.
Innovation Solution
An attraction state inspection device is designed with a diffusion member inside the nozzle group to diffuse incident light, an image pickup unit positioned apart to capture images against the diffusion member as a background, and an irradiation unit placed to radiate light in a way that intersects the diffusion member, allowing for high contrast imaging of parts attracted by nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the LED is disposed on the CCD camera side to illuminate the part, then the inspection device can be compact, but light reflected by the part enters the CCD camera causing low contrast and decreased recognition accuracy
Solution Approach 1:
A diffusing member is introduced as an intermediary between the LED and the CCD camera. This diffusing member scatters the light from the LED, preventing direct reflected light from entering the camera while still providing sufficient illumination. The diffusing member acts as a mediator that transforms the direct light into scattered light, resolving the contradiction between compact design and image contrast.
2Measurement precision
If an optical filter is disposed between the CCD camera and LED to block reflected light, then recognition accuracy improves, but device size and cost increase
Solution Approach 1:
Instead of using an optical filter as an intermediary, the patent employs a diffusing member that achieves the same goal of improving image contrast through a different mechanism. The diffusing member scatters light rather than filtering specific wavelengths, which avoids the need for additional optical components and keeps the device compact while maintaining high recognition accuracy.
3Measurement precision
If an optical filter is added to block reflected light, then recognition accuracy improves, but device cost increases due to need for more LEDs to compensate light loss
Solution Approach 1:
The diffusing member serves as an intermediary that redistributes light rather than blocking it. This approach maintains overall light quantity while improving contrast, eliminating the need to add more LEDs to compensate for light loss that would occur with filtering methods.
4Measurement precision
If the irradiation unit is disposed to avoid the optical path, then light interference is reduced, but the quantity of light decreases or the irradiation unit size must be increased
Solution Approach 1:
The diffusing member is positioned as an intermediary between the irradiation unit and the part, transforming direct light into scattered light. This allows the irradiation unit to be positioned without directly interfering with the optical path to the camera, while still providing sufficient illumination through scattered light distribution.
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
This configuration enables high-contrast imaging of parts attracted by nozzles, improving recognition accuracy without increasing device size or cost, and allows for efficient inspection even when multiple nozzles are present.
Implementation Method 1
a diffusion member that is disposed inside a nozzle group in which a plurality of nozzles that attract parts are disposed, and transmits incident light while diffusing the light
Implementation Method 2
an irradiation unit that is disposed at a position in which a virtual line extending from the image pickup unit in a second direction opposite the first direction intersects the diffusion member, and in a region opposite the image pickup unit so as to sandwich therebetween a virtual vertical plane passing through a virtual horizontal line perpendicular to the virtual line, and that radiates light toward the nozzle group
Implementation Method 3
a reflector is disposed on the axial line. In other words, a plurality of attraction nozzles are disposed so as to surround the reflector. A CCD (Charge Coupled Device) camera and a LED (Light Emitting Diode) are provided at one side of the nozzle group of such a configuration. A two-dimensional image of an electronic part attracted to the distal end of the attraction nozzle is picked up with the CCD camera by using light reflected by the reflector
Data Source
AI summary
An attraction state inspection device includes a diffusion member that is disposed inside a nozzle group in which a plurality of nozzles that attract parts are disposed, and transmits incident light while diffusing the light, an image pickup unit that is disposed on a side of the nozzle group apart from the diffusion member in a first direction, picks up an image of a part that is attracted by one nozzle positioned in the first direction with respect to the diffusion member, from among the plurality of nozzles constituting the nozzle group, against a background of the diffusion member, and obtains an image of the part, an irradiation unit that is disposed opposite the image pickup unit with the diffusion member interposed therebetween, and radiates light toward the nozzle group, and an inspection unit that inspects an attraction state of the part attracted by the one nozzle on the basis of the image of the part picked up by the image pickup unit.