Vision System FOVE Optical Path Folding
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Solution Overview
Problem
Vision systems face limitations in expanding their field of view without compromising resolution, particularly in applications where objects of varying sizes and spaces require wide coverage, leading to challenges in accurately imaging and decoding IDs across the entire width of a conveyor or large objects.
Innovation Solution
A system and method that employs a field of view expander (FOVE) using mirrors and optics to redirect and fold optical paths, allowing multiple image sensors to be positioned closer together, thereby increasing the field of view without decreasing resolution and optimizing pixel mapping for different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple ID readers/cameras are employed side by side to cover the width of the line, then the field of view is expanded, but the system cost and complexity increase
Solution Approach 1:
The patent combines multiple camera systems into a single integrated vision system with a unified processor that handles images from all cameras. This merging approach expands the field of view while avoiding the complexity of multiple independent systems, as the centralized processor coordinates all imaging and decoding operations from a single control unit.
Solution Approach 2:
The vision system processor is designed to handle multiple functions including imaging, barcode decoding, and coordinate transformation across multiple cameras. This multi-functional approach allows a single system to perform the work of multiple specialized devices, expanding coverage without proportionally increasing system complexity.
2Area of stationary object
If a larger sensor is employed in the single ID reader, then the field of view is expanded, but the cost increases and resolution in the height direction is unnecessarily increased
Solution Approach 1:
Instead of using one large sensor, the patent divides the imaging task across multiple standard sensors arranged in an array. Each sensor captures a portion of the overall scene, and the processor combines these segmented images to create a complete view. This segmentation allows the use of conventional, cost-effective sensors while achieving the desired wide field of view.
Solution Approach 2:
The patent transitions from expanding field of view in the horizontal dimension using a single sensor to achieving wide coverage through spatial arrangement of multiple sensors in an array configuration. This dimensional approach allows coverage expansion without requiring larger individual sensor elements, maintaining cost-effectiveness and avoiding unnecessary resolution increases in the height direction.
3Area of stationary object
If the focal distance is increased to maintain resolution, then the field of view is reduced, but if the focal distance is decreased, then the resolution of IDs varies depending on object placement
Solution Approach 1:
The vision system incorporates dynamic focal adjustment capabilities that allow the processor to optimize focus for objects at different distances and positions within the expanded field of view. This dynamic adaptation ensures consistent ID resolution across varying object placements while maintaining the wide field of view provided by the multiple-camera configuration.
Solution Approach 2:
The system uses feedback from image quality analysis to automatically adjust focal settings and ensure optimal ID resolution. The processor monitors the captured images and adjusts focusing parameters based on the actual position and clarity of objects, maintaining consistent measurement precision across the entire expanded field of view.
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 FOVE system effectively expands the field of view while maintaining resolution, allowing for accurate imaging and decoding of IDs across wider areas without the need for additional hardware, and can be adapted for space-constrained environments.
Implementation Method 1
A system and method for expanding a field of view of a scene imaged by a vision system camera assembly having an image sensor defining an image plane are provided. In one embodiment, at least two mirrors redirect and fold the optical path relative to the camera assembly so as to define at least four partial fields of view (FOVs) of a scene along four respective optical paths.
Data Source
AI summary
This invention provides a system for separating a field of view (FOV) of a scene imaged by a vision system camera assembly, in which a separating mirror assembly redirects a first optical path of at least a first optics with respect to at least a first image sensor in the camera assembly. A first reflecting assembly redirects the first optical path from the separating mirror toward a first FOV. The first optical path is extended free of splitting the image. The separating mirror assembly redirects a second optical path of a second optics with respect to a second image sensor in the camera assembly. A second reflecting assembly redirects the second optical path from the separating mirror toward a second FOV. The second optical path is extended free of splitting the image projected from the scene on the second image sensor.