Elongated Object Inspection Using Single-Imager 360-Degree Reflector Sets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Capturing highly accurate images of elongated objects during high-speed inspection is costly due to the need for high-performance imagers and control devices.
Innovation Solution
An appearance inspection device for elongated objects uses a single imager with multiple reflector sets to capture images around the object's periphery, adjusting optical path lengths to fit within the imager's depth of field, reducing costs while maintaining imaging performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple imagers are used to capture images of the elongated object along the full periphery, then imaging coverage and inspection accuracy are improved, but device cost and complexity increase
Solution Approach 1:
The imaging system is segmented into multiple reflector sets, each responsible for a specific angular sector. By dividing the 360-degree perimeter into multiple segments and using separate reflectors for each sector, the patent achieves comprehensive coverage with a single imager, avoiding the need for multiple imagers while maintaining inspection accuracy.
Solution Approach 2:
Reflector sets act as intermediaries between the single imager and the elongated object. The reflectors redirect light from the object's periphery back to the imager, enabling the imager to capture images from multiple angular positions without physically moving or requiring multiple imaging elements, thus reducing device complexity.
2Measurement precision
If high-performance imagers with high resolution and short sampling period are used, then imaging quality is improved, but device cost increases
Solution Approach 1:
Instead of using one expensive high-performance imager for the entire 360-degree perimeter, the patent segments the imaging task across multiple reflector sets. Each reflector set captures a specific angular sector, allowing the use of standard imagers that are less expensive but collectively provide the same comprehensive coverage and resolution through coordinated operation.
Solution Approach 2:
The single imager is designed to serve multiple functions by capturing images from different angular positions through the reflector sets. This multi-functional capability allows one imager to replace what would traditionally require multiple specialized imagers, reducing overall system cost while maintaining high imaging quality through the imager's high-resolution sensor and short sampling period.
3Measurement precision
If the optical path length is extended to capture more of the object periphery, then inspection coverage is improved, but depth of field requirements increase
Solution Approach 1:
The optical paths are segmented into multiple independent reflector sets, each with a controlled length corresponding to a specific angular sector. By limiting the optical path length in each segment rather than extending a single long path, the patent maintains depth of field within acceptable ranges while achieving comprehensive 360-degree inspection coverage through the collective action of all reflector sets.
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 device achieves 360-degree inspection with a single imager, reducing size and cost, and improves accuracy by minimizing optical path length differences.
Implementation Method 1
Each of the plurality of reflectors included in each of the plurality of reflector sets includes a reflecting portion in a plane perpendicular to an axis of the elongated object and within an angle of view of the imager in the axial direction
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An appearance inspection device for an elongated object includes a high-performance imager at reduced cost without lowering the imaging performance. An appearance inspection device (10) for an elongated object includes an imaging unit (12) that captures an image of a periphery of an elongated object (11). The imaging unit (12) includes an imager (20) and reflector sets each including multiple reflectors combined to define an optical path extending from the imager (20) to the elongated object (11). Each reflector included in each reflector set is located within a predetermined range. The optical path extending in each reflector set from the imager (20) to the elongated object (11) has a length within a predetermined range. This structure allows the appearance of the elongated object to be fully inspected around 360 degrees about the axis with a single costly imager. The inspection device is thus less costly.