Fused Imaging Device for Defect Detection on Diverse Surfaces
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Solution Overview
Problem
Conventional light sources are inadequate for capturing high-quality images of industrial products with diverse surface materials and defects, such as reflective, transparent, or black surfaces, and are not compatible with various environments, leading to reduced accuracy in defect detection.
Innovation Solution
A fused imaging device comprising a light source component with customizable LEDs or flexible screens, an image capture component, and a control component that adjusts lighting configurations, incidence angles, and wavelengths to capture multiple images and generate a target image, improving defect detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional single light source is used, then the device complexity is low, but the image quality and defect detection accuracy deteriorate when capturing products with diverse surface materials and defects
Solution Approach 1:
The light source is divided into multiple independent LED elements arranged in a matrix pattern, where each LED can be independently controlled. This segmentation allows different regions of the light source to provide different lighting conditions (e.g., directional light for reflective surfaces, diffuse light for transparent surfaces), thereby improving defect detection accuracy across diverse product surfaces without requiring a completely complex reconfigurable system
Solution Approach 2:
Different LED elements in the matrix are selectively activated based on the specific imaging requirements. For example, certain LEDs are activated to provide directional illumination when capturing reflective surfaces, while other LEDs are activated for diffuse illumination when capturing transparent or matte surfaces. This local quality approach optimizes lighting for specific surfaces without requiring the entire light source to be complex
2Adaptability or versatility
If multiple lighting configurations are implemented to capture diverse surface materials, then the adaptability improves, but the number of images to process and time required increases
Solution Approach 1:
The light source transitions from a static single configuration to a dynamic multi-configurable system where LED matrices can be rapidly reconfigured between different lighting patterns (directional, diffuse, structured). This dynamic capability allows the system to adapt to diverse surface materials (reflective, transparent, matte) by simply changing the activation pattern of LED elements, providing versatility without requiring physical reconfiguration or extensive manual adjustment
Solution Approach 2:
Multiple lighting configurations are pre-programmed into the system, allowing the optimal lighting pattern to be selected and applied automatically based on the product type or surface characteristics before image capture begins. This preliminary preparation eliminates the need for time-consuming manual adjustment during operation
3Measurement precision
If conventional light sources are used, then the ease of operation is high, but the image quality deteriorates for specific surface types such as reflective, transparent, or black surfaces
Solution Approach 1:
The system incorporates automated control that selects and activates the appropriate LED matrix configuration based on pre-programmed criteria or user input about the product type. The control system automatically adjusts which LED elements are active, eliminating the need for manual intervention in the complex lighting configuration while ensuring optimal image quality for the specific surface being captured
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 device ensures high-quality image capture across multiple surface materials and environments, enhancing the accuracy of defect detection by using customizable lighting configurations and advanced image processing.
Implementation Method 1
The light source includes a plurality of LEDs and/or flexible screens
Implementation Method 2
The light source component includes a plurality of light sources disposed on an interior surface of a shell of the light source component
Implementation Method 3
surface materials or characteristics on products that affect light quality of a captured image include reflective qualities
Data Source
AI summary
A fused imaging device and method are disclosed. The device comprises a light source component, an image capture component, and a control component. The control component may be configured to control the light source component to illuminate a target object based on a preset plurality of first optimal lighting configurations. The control component may further control the image capture component to capture images of the target object to obtain multiple first images, under the illumination of the light source component and generate a target image of the target object, based on the first images. The control component may further adjust the incidence angle, pattern, and wavelength of the light source in the light source component, as well as the exposure, lens focus, and polarization of the image capture component, to detect target object defects in captured images of the target object.