Inspection Roller Engraved Reference for Shadow-Free Calibration
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Solution Overview
Problem
The use of stickers as reference marks on rollers in inspection apparatuses for calibrating defects and dimensions in electrode sheets creates shadows and potential scratches, complicating the calibration process and decreasing its frequency.
Innovation Solution
Incorporating an engraved portion, such as grooves, on the conveyor roller surface as a non-contact reference for inspection, which diffuses light and allows for continuous calibration without interfering with the workpiece, enabling simultaneous imaging of the engraved portion and the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sticker is used as a reference mark on the roller, then calibration can be performed, but the sticker casts a shadow that interferes with image capture and requires precise positioning
Solution Approach 1:
The reference mark is extracted from the contact region and placed in the non-contact region of the roller surface. This separation eliminates the shadow problem and positioning constraints while maintaining calibration functionality, as the reference mark no longer interferes with workpiece conveyance or image capture lighting
Solution Approach 2:
The reference mark is positioned in a different spatial dimension (non-contact region) relative to the workpiece contact region. This dimensional separation allows the reference mark to be captured without shadow interference while the workpiece continues to be conveyed normally in the contact region
2Measurement precision
If a sticker with thickness is left on the roller during inspection, then calibration reference is available, but the sticker contacts the workpiece and forms scratches or impressions
Solution Approach 1:
The roller surface is segmented into two functional regions: a contact region for workpiece conveyance and a non-contact region for the calibration reference mark. This segmentation allows the reference mark to exist without contacting the workpiece, eliminating damage while preserving calibration capability
Solution Approach 2:
The reference mark is taken out from the workpiece contact path and positioned in the non-contact region. This extraction eliminates the harmful contact between the sticker and workpiece while maintaining the reference mark's availability for calibration purposes
3Illumination intensity
If the sticker is positioned immediately below the lighting device to avoid shadows, then shadow formation is prevented, but the workpiece must be removed from this region before capturing the reference mark image
Solution Approach 1:
The reference mark is positioned in the non-contact region, which is a different spatial zone from the workpiece conveyance path. This allows simultaneous capture of both workpiece and reference mark without requiring workpiece removal, maintaining both illumination quality and operational continuity
Solution Approach 2:
The calibration reference mark remains continuously available in the non-contact region during workpiece inspection. This continuity allows calibration to be performed at any time without interrupting workpiece conveyance or requiring removal of the workpiece, thereby maintaining high productivity
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 solution simplifies the calibration process by allowing frequent and simultaneous inspection of the workpiece without shadows or interference, improving the accuracy and frequency of calibration.
Implementation Method 1
using grooves that diffuse light and provide a distinct tone difference for edge detection
Data Source
AI summary
An inspection apparatus includes a support, an image capturing unit, and a controller. The support supports a workpiece. The image capturing unit generates captured image data including an image of the workpiece. The controller executes image processing on the captured image data to evaluate the workpiece. The support includes an engraved portion, including a groove and serving as a reference for inspection, on a surface of the support in a non-contact region that is free from contact with the workpiece. The engraved portion is included in an image capturing range of the image capturing unit. The controller evaluates the workpiece using a dimension of the engraved portion that is stored in the controller in advance and a reference image that is an image of the engraved portion.