Filament Inspection Using Single Camera and Mirrors
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Solution Overview
Problem
Current filament inspection systems for 3D printers are costly and inefficient, particularly when dealing with variations in physical and chemical properties along the length of thermoplastic filament, leading to unnecessary discarding or recycling of filaments.
Innovation Solution
A cost-effective filament inspection system utilizing a single video camera and two mirrors to image the exterior surfaces of filaments, combined with a simple electrical network to analyze permittivity, allowing for the characterization of physical and chemical properties of each segment, including fiber-reinforced thermoplastic filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single video camera and two mirrors are used to image filament surfaces, then the system cost is reduced, but the ability to capture complete exterior surfaces from multiple angles becomes limited
Solution Approach 1:
The patent uses two mirrors positioned at different angles to reflect light from different portions of the filament surface into the single camera sensor. This creates a multi-dimensional optical path that allows a single 2D sensor to capture information about the 3D surface geometry and defects across the entire filament circumference, effectively expanding the imaged surface area without adding more cameras.
2Measurement precision
If traditional multi-camera systems are used to inspect filament, then complete surface coverage is achieved, but the system complexity and cost increase
Solution Approach 1:
The patent merges the functions of multiple cameras into a single camera system by using optical mirrors to combine multiple light paths. The single camera captures images of the filament surface from multiple reflected angles, achieving complete surface coverage that would otherwise require multiple cameras, thereby reducing system complexity while maintaining inspection completeness.
Solution Approach 2:
The mirrors serve as intermediary optical elements that redirect light from different portions of the filament surface to the camera sensor. These intermediaries enable a single camera to indirectly observe surfaces that would be invisible from its direct line of sight, achieving comprehensive surface inspection without multiple cameras.
3Measurement precision
If empirical data on permittivity is collected for each filament segment, then chemical property characterization is improved, but the complexity of the electrical network increases
Solution Approach 1:
The patent measures permittivity (electrical parameter) of filament segments to characterize chemical properties such as fiber reinforcement content, dispersion, and wetting. By using a simple electrical network to measure this single key parameter, the system achieves comprehensive chemical characterization without requiring complex multi-parameter measurement systems, thus maintaining low complexity while improving measurement precision.
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
Enables efficient characterization of filament properties, reducing waste by identifying only non-compliant segments and allowing for targeted cutting, thereby optimizing filament usage and reducing costs.
Implementation Method 1
a second image of a second radial profile of the segment of the filament in the path from a second radial perspective, wherein the second image is received by the camera via reflection in the first mirror, and (3) a third image of a third radial profile of the segment of the filament in the path from a third radial perspective, wherein the third image is reflected into the camera by the second mirror
Data Source
AI summary
A filament inspection system is disclosed that gathers empirical data on the physical and chemical properties of filament. The illustrative embodiments need only a single video camera and two mirrors to image all of the exterior surfaces of one or more filaments simultaneously. These images can be used to analyze the physical properties of the filament. Furthermore, the illustrative embodiments need only a simple electrical network to gather empirical data on the permittivity of each segment of filament, which gives insights into the chemical properties of the filament. For example, embodiments of the present invention are particularly well suited for inspecting fiber-reinforced thermoplastic filament, and variations in the number, dispersion, wetting, and length of the fibers are all observable in variations in permittivity.