Foreground Illumination Calibration for Sample Tube Imaging
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Solution Overview
Problem
Existing imaging systems for sample containers exhibit variations in performance and consistency, particularly in the characterization of cap color and shape, which can lead to incorrect sample tube usage and erroneous test results.
Innovation Solution
A calibration method involving multiple light sources and a calibration tool with known reflectance is employed to adjust drive currents for uniform illumination, ensuring consistent foreground illumination across imaging apparatus, allowing for precise characterization of sample tube features such as cap color and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple light sources are used for illumination, then illumination coverage and uniformity are improved, but system complexity and calibration difficulty increase
Solution Approach 1:
A calibration tool with a diffuse reflectance surface is introduced as an intermediary object between the light sources and the imaging system. This calibration tool provides a known, uniform reflectance reference that enables the system to measure and adjust the combined illumination from multiple light sources, achieving uniformity without directly controlling each light source individually.
Solution Approach 2:
The system adjusts the drive current of each light source to change their output intensity parameters. By varying these electrical parameters, the system optimizes the contribution of each light source to achieve uniform overall illumination across the imaging area, resolving the contradiction between using multiple sources and maintaining simplicity.
2Reliability
If drive current adjustment is performed to achieve uniform illumination, then imaging consistency is improved, but calibration time and process complexity increase
Solution Approach 1:
The calibration process is performed in advance during system setup or maintenance periods, establishing the optimal drive current settings for each light source before actual sample imaging begins. This preliminary calibration ensures consistent imaging performance throughout operation without affecting production throughput.
Solution Approach 2:
The system performs self-calibration by automatically measuring the illumination uniformity using the calibration tool and adjusting the drive currents of the light sources based on measured deviations. This automated feedback loop reduces manual intervention and minimizes calibration time while ensuring imaging consistency.
3Measurement precision
If calibration tool with known reflectance is used, then measurement accuracy is improved, but additional equipment and setup complexity increase
Solution Approach 1:
The calibration tool features a homogeneous diffuse reflectance surface with known, uniform optical properties across its area. This homogeneity provides a consistent reference standard that simplifies the calibration process, as the system only needs to account for one known reflectance value rather than mapping complex spatial variations.
Solution Approach 2:
The calibration tool is designed as a simple, inexpensive component that can be easily replaced if needed. Its straightforward design with a diffuse reflectance surface avoids complex mechanisms, reducing both equipment cost and setup complexity while maintaining measurement accuracy.
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
Ensures accurate and consistent imaging of sample container features, preventing incorrect sample tube usage and improving the reliability of analytical tests by ensuring proper alignment with intended test protocols.
Implementation Method 1
replacing the calibration tube with a calibration tool having a calibration surface of a known reflectance; and measuring target intensity values of the calibration tool
Data Source
AI summary
A method of calibrating an imaging device adapted to characterize a feature of a sample container, such as a cap color or cap type. The method includes providing a calibration tube including an imaging surface at an imaging location of a first imaging apparatus; illuminating the imaging surface with light emitted from multiple front light sources; adjusting a drive current to each of the multiple front light sources to establish a substantially uniform intensity of the imaging surface; recording drive current values for the multiple front light sources; replacing the calibration tube with a calibration tool having a calibration surface of a known reflectance; and measuring target intensity values of the calibration tool at the respective drive current values. Calibration tools, imaging apparatus, quality check modules, and health check methods are provided, as are other aspects.