Automated Golf Ball Inspection Using Multi-Exposure Imaging
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Solution Overview
Problem
Existing automated inspection systems for golf balls have limitations in detecting defects due to low dynamic range imaging, which can obscure fine details and fail to detect defects not visible in specific electromagnetic ranges, leading to potential production of defective products.
Innovation Solution
An automated inspection system that captures multiple images with different optical properties using low dynamic range or high dynamic range digital image sensors, combining images with varying exposure values to produce a high dynamic range image, and optionally incorporating non-visible range sensors to detect surface and subsurface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If low dynamic range digital image sensors are used to capture images, then the device complexity is reduced, but the measurement precision deteriorates due to obscured fine details
Solution Approach 1:
The imaging process is segmented into multiple exposures of the same scene with different exposure values. Instead of attempting to capture the full dynamic range in a single image, the system divides the capture process into multiple discrete images, each optimized for specific luminance ranges, which are then combined to achieve high dynamic range output.
Solution Approach 2:
The system transitions from capturing images in a single luminance dimension to capturing images across multiple luminance dimensions (different exposure values). By adding the dimension of exposure variation, the system can represent a much wider range of luminance values, effectively solving the dynamic range limitation without requiring complex sensor hardware.
2Measurement precision
If multiple images with different exposure values are captured and combined, then the measurement precision improves by capturing fine details across luminance ranges, but the loss of time increases due to multiple capture cycles
Solution Approach 1:
The system uses rapid sequential exposure to capture multiple images of the same scene, rushing through the capture process before any significant change occurs in the inspected object. This allows multiple exposures to be taken in quick succession, minimizing the time delay and ensuring that the captured images represent the same moment in time.
3Reliability
If inspection is performed after clear coat curing, then the reliability of defect detection improves, but the loss of time increases as defects cannot be identified early in the process
Solution Approach 1:
The inspection is performed preliminarily, immediately after clear coat application but before the curing process completes. By conducting the inspection at this intermediate stage, the system can detect defects early in the production process, allowing for timely corrective action without waiting for the full curing cycle to complete, thus reducing waste and improving efficiency.
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 provides improved visual detail and detection capabilities, enabling early identification of defects and maintaining high production quality by capturing a wider range of defects without complex lighting, thus allowing for timely correction of manufacturing issues.
Implementation Method 1
low dynamic range or high dynamic range digital image sensors
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.