Dome Reflector Inspection Lighting for Reduced Illumination Dead Spots
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Solution Overview
Problem
The existing inspection devices face a challenge of creating a 'dead spot' where illumination light is absent due to the need for a larger through-hole for additional inspection apparatuses, leading to reduced measurement accuracy.
Innovation Solution
The inspection device incorporates a configuration with dome-shaped reflector plates and annular light sources that illuminate the inspection object, with the optical axes of inspection apparatuses passing through through-holes in the reflector plates, reducing the dead spot and improving measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the through-hole diameter in the reflector plate is increased to accommodate additional inspection apparatuses, then the adaptability and versatility of the inspection device is improved, but a dead spot is created where illumination light is absent, causing measurement precision to decline
Solution Approach 1:
The single large through-hole is segmented into multiple smaller through-holes, each accommodating a specific inspection apparatus. This segmentation allows multiple apparatuses to be installed while maintaining adequate illumination coverage, as each smaller hole creates a minimal dead spot that can be managed by the annular light source configuration.
Solution Approach 2:
The annular light sources are positioned to provide localized illumination specifically targeted at the dead spots created by the through-holes. This local quality approach ensures that illumination is concentrated where needed most, compensating for the areas where light would otherwise be blocked by the inspection apparatuses.
2Adaptability or versatility
If multiple inspection apparatuses are installed on the reflector plate, then the functionality and inspection capabilities are improved, but the device complexity increases due to the need for multiple through-holes and light sources
Solution Approach 1:
The reflector plate is designed with multiple through-holes that can accommodate various types of inspection apparatuses (imaging units, projection units, etc.). This universal design allows the same structural framework to support diverse inspection functions, reducing the need for separate specialized structures for each apparatus type.
Solution Approach 2:
The annular light sources are nested within the reflector plate structure, with each light source positioned in a specific radial location. This nesting approach allows multiple light sources to be integrated into the existing reflector plate without requiring separate mounting structures, thereby reducing overall device complexity.
3Measurement precision
If annular light sources are used to illuminate the reflector plate, then the dead spot is reduced and illumination uniformity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The annular light sources follow a curved, circular arrangement around the optical axis, matching the dome-shaped geometry of the reflector plate. This curvilinear configuration naturally distributes light uniformly across the inspection surface and simplifies the optical design by leveraging the existing spherical symmetry of the reflector plate.
Solution Approach 2:
The annular light sources are integrated with the reflector plate as a unified structure, where the light sources and reflector surface work together as a combined illumination system. This merging eliminates the need for separate complex mounting and alignment mechanisms, thereby reducing manufacturing complexity while maintaining illumination uniformity.
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 effectively minimizes the dead spot and enhances measurement accuracy by ensuring uniform illumination and improved resolution, particularly when capturing images from different angles.
Implementation Method 1
uses an illuminating unit including a dome-shaped reflector plate arranged so as to cover the imaging object from a vertical direction to irradiate the imaging object with illumination light by reflecting light from a light source with the reflector plate
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
To provide an inspection device capable of reducing a dead spot of illumination light on an imaging object and improving measurement accuracy. An inspection device 10 includes: a first image unit 21 that captures an image of an inspection object 12 from a vertical direction; a plurality of dome-shaped reflector plates 230a to 230c being arranged between the first image unit 21 and the inspection object 12 and having aperture parts 233 to 236 on a side of the first image unit 21 and a side of the inspection object 12, respectively; a plurality of annular light sources 23a to 23c that illuminate the respective reflector plates 230a to 230c; and apparatuses for inspection (second image unit 22 and projection unit 24) that are provided outside of the reflector plates 230a to 230c and are capable of capturing an image of the inspection object 12 or irradiating the inspection object 12 with light, wherein optical axes of the apparatuses for inspection are arranged so as to pass through through-holes 237 and 238 provided in the reflector plates 230a to 230c.