Automated Golf Ball Inspection Using Multi-Exposure Imaging
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Solution Overview
Problem
Existing automated inspection systems for golf balls, particularly those using low dynamic range image processing, struggle to detect minute defects and inconsistencies in coating coverage due to limited light dynamic range, which can lead to defective products being overlooked and compromising production quality.
Innovation Solution
An automated inspection system that captures multiple images of golf balls with different optical properties, using a combination of visible and non-visible electromagnetic range sensors, and combines these images to produce high dynamic range images, allowing for detailed analysis of surface and subsurface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If low dynamic range image processing is used in automated inspection systems, then the system complexity is reduced and manufacturing speed is maintained, but the detection precision of minute defects and coating inconsistencies deteriorates
Solution Approach 1:
The inspection system segments the imaging process by capturing multiple images at different exposure levels (underexposed, normally exposed, overexposed) to capture different luminance ranges. This segmentation allows the system to overcome the limitations of low dynamic range sensors while maintaining system simplicity, as each individual image can be processed with standard low dynamic range image processing techniques.
Solution Approach 2:
The system transitions from a single-dimension (single exposure level) imaging approach to a multi-dimensional approach by combining images taken at different exposure levels. This dimensional expansion in the exposure domain enables the system to achieve high dynamic range detection capabilities without requiring complex high dynamic range hardware, thereby resolving the contradiction between detection precision and system complexity.
2Measurement precision
If multiple images with different exposure values are captured and combined, then the detection of defects with improved visual detail is achieved, but the inspection time and processing complexity increase
Solution Approach 1:
The system maintains continuous inspection by capturing multiple exposure images in rapid succession during the golf ball's movement through the inspection station. The images are captured continuously as the ball rotates and passes by, eliminating the need to stop the production line for additional imaging, thus minimizing inspection time while achieving enhanced visual detail.
Solution Approach 2:
The inspection system uses periodic capture of images at different exposure levels as the golf ball rotates through the inspection field. By synchronizing the image capture with the rotational position and lighting cycles, the system efficiently collects all necessary exposure variations without requiring excessive imaging time, thereby reducing overall inspection time while maintaining high detection precision.
3Productivity
If automated processing stations function at optimal efficiency and speed, then productivity is improved, but manufacturing defects such as smudges, vibration marks, and coating inconsistencies occur more frequently
Solution Approach 1:
The inspection system provides immediate feedback by detecting defects such as smudges, vibration marks, and coating inconsistencies during the production process. This real-time feedback enables operators to identify and correct manufacturing issues promptly while the automated processing stations are still running at optimal speed, thus maintaining both high productivity and product reliability without requiring a reduction in production rate.
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 system effectively enhances the detection of defects by providing improved visual detail and contrast, enabling operators to identify and correct manufacturing issues promptly, thereby maintaining high production quality and reducing the production of defective balls.
Implementation Method 1
a first image is exposed for a short amount of time to capture the brightest or most reflective areas of the scene in detail... A second image is exposed for a moderate length of time to capture areas of the scene that are moderately bright or reflective in detail... A third image is exposed for the longest amount of time to capture dark or shadowed areas of the scene in detail
Implementation Method 2
The vision engine then combines the separate images into one image that shows nearly all areas of the scene in detail... providing said image with a high light dynamic range
Data Source
AI summary
An automated object inspection system is presented. The inspection system includes an imaging system to produce at least two images of said object having different optical properties and an analyzer coupled to the imaging system to receive the images and to perform a variety of inspection operations on said images. The imaging system may produce images of the object under inspection in the visible range having varying exposure values. A vision engine included in the analyzer may combine said images through an algorithmic process into one image having high light dynamic range. Alternatively, the imaging system may produce images of the object in the visible or non-visible electromagnetic range. The analyzer may perform inspection routines on said images. An imaging system capable of producing digital video is presented, wherein each frame of video produced by said camera is composed of multiple images having different optical properties.