Five-Axis Optical Inspection System with Rotating Mirror
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional five-axis motion systems for optical inspection of parts with complex contours are inefficient due to increased mass and size, leading to slower inspection speeds and challenges in lighting and image quality, particularly when using dual rotary tables or adding mass to existing axes.
Innovation Solution
A five-axis inspection system with a camera and lens mounted on a rotational stage attached to a Z-axis, utilizing a computer numerically controlled right-angle reflector to redirect the optical axis and minimize mass and space, combined with a large area camera and extended depth of focus for high-speed imaging and uniform illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dual rotary table configuration is used to achieve fifth axis motion, then the part can be inspected from multiple angles, but the mass increases significantly making inspection operations slower
Solution Approach 1:
The fifth axis motion is segmented into two independent rotary tables, each responsible for specific angular ranges. This allows the system to achieve full spherical inspection coverage while minimizing the mass that needs to be accelerated at any given time, thereby maintaining high inspection speeds.
Solution Approach 2:
The patent transitions from a single rotary table approach to a dual rotary table configuration, adding a dimensional aspect to the motion system. This enables independent control of two rotational axes, providing versatile multi-angle inspection capability while distributing the mass burden across two separate, lighter rotary tables rather than one heavy dual-axis system.
2Adaptability or versatility
If a dual rotary table configuration is used, then fifth axis motion is achieved, but lighting the part becomes more challenging
Solution Approach 1:
The dual rotary table system is designed to accommodate multiple lighting configurations simultaneously. The open architecture allows integration of various light sources (coaxial, oblique, dark field) that can be independently controlled, enabling the system to handle diverse inspection requirements and lighting challenges that would be difficult to manage in a single rotary table configuration.
3Adaptability or versatility
If the camera and lens components are mounted on a rotational stage attached to a Z-axis, then fifth axis motion is achieved, but the mass on the Z-axis increases
Solution Approach 1:
The rotational stage is segmented into modular components with the camera and lens mounted on a separate rotational platform. This segmentation allows the Z-axis to support only the lightweight camera assembly rather than the entire inspection system, significantly reducing the mass burden on the Z-axis while still achieving fifth axis motion capability.
4Adaptability or versatility
If the optical track length is increased to accommodate the stage travel, then the system can achieve fifth axis motion, but the system size and cost increase
Solution Approach 1:
The patent employs a rotational stage that introduces angular motion in addition to the linear Z-axis travel. This dimensional addition allows the optical system to achieve fifth axis motion without requiring proportionally long linear optical tracks, as the rotational component provides the necessary field of view and positioning flexibility.
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 high-resolution, high-speed imaging of complex parts with minimal stage travel and system size, while providing uniform illumination and improved image quality through bright field illumination and reduced mechanical complexity.
Implementation Method 1
a computer numerically controlled right angle reflector 15 is then utilized to bend the traditionally downward facing optical axis 16 by 90 degrees
Implementation Method 2
A lens 4 and camera 1 are mounted on a rotational stage 8
Data Source
Figure 1
Figure 2
AI summary
An inspection system that is effective to collect images of a part (7) under inspection. This inspection system includes (a) a three axis linear motion stage (10); (b) a rotary fourth axis stage (11) configured to hold and rotate an object (7) to be inspected. This rotary fourth axis stage (11) is mounted on the three axis linear stage (10); (c) a fifth axis camera (1) and optical system (4) mounted to one of the axes of the three axis linear motion stage (10). This fifth axis camera (1) has an optical axis substantially parallel to the axis of linear motion; (d) a 45 degree mirror (6) configured to bend the optical axis of the fifth axis camera (1) by 90° to point towards the object (7); and (e) a motor (3) configured to rotate the mirror (6) over a range of angles to obtain a fifth axis of viewing orientation.