Illumination Apparatus Power Extraction Module
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Solution Overview
Problem
Machine vision systems in manufacturing environments face challenges due to the need for multiple long cables for power and data transmission between cameras and controllers, which complicates wiring and increases costs, especially in tight spaces.
Innovation Solution
A light illumination apparatus that integrates power and data streams within a single cable, using a power extraction module to convert and provide separate power voltages for the camera and illuminator, reducing the need for multiple cables by using short power and data cables between the light illumination apparatus and camera.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate cables are used for power and data transmission between camera and controller, then reliable power delivery and data communication are achieved, but wiring complexity and installation costs increase significantly
Solution Approach 1:
The patent combines multiple separate cables (power cable and data cable) into a single integrated cable that carries both power and data signals. The connector includes multiple contacts that simultaneously transmit power at different voltages and data signals, reducing the number of cables from three to one and simplifying the wiring infrastructure while maintaining reliable power delivery and data communication
Solution Approach 2:
The integrated cable and connector design serves multiple functions simultaneously: it provides power transmission at different voltages (24V for illuminator, 12V for camera), carries data signals for image transmission, and enables synchronization between camera and illuminator operations. This multi-functional approach eliminates the need for separate dedicated cables for each function
2Ease of operation
If multiple long cables are routed through tight spaces in production environment, then power and data connections are established, but installation difficulty and labor costs increase
Solution Approach 1:
By merging power and data transmission into a single integrated cable, the patent reduces the total cable length required and simplifies routing through tight spaces. Instead of managing three separate long cables (two power cables and one data cable), the system uses one integrated cable, making installation and repositioning significantly easier in constrained manufacturing environments
3Adaptability or versatility
If separate power supplies are used for illuminator and camera, then specific voltage requirements are met, but system maintenance costs and complexity increase
Solution Approach 1:
The integrated cable system provides universal power delivery capability, supporting multiple voltage levels (24V for illuminator, 12V for camera) through a single connection. The connector includes dedicated contacts for different voltage rails, allowing the system to adapt to the specific power requirements of both devices simultaneously, eliminating the need for separate power supplies and reducing maintenance complexity
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
This solution simplifies cabling, reduces installation and maintenance costs, and improves the efficiency of machine vision systems by allowing for longer cable runs with fewer cables, enhancing the flexibility and reliability of image capture and illumination in manufacturing environments.
Implementation Method 1
a power extraction module coupled to the first connector, the second connector, and the illumination module, the power extraction module adapted to extract the source power component from the integrated power and data stream, extract the data stream component from the integrated power and data stream, communicate the data stream component between the first connector and the second connector, convert a first portion of the source power component to the first power component at the first voltage, apply the first power component to the illumination module, supply a second portion of the source power component to the second power component, provide the second power component to the external camera apparatus
Data Source
AI summary
Power for an illumination device and a camera is provided from power integrated onto a data cable between a controller/computer and the light illumination device. The camera-controller/computer interface includes one of GEV with PoE, USB and CXP, where a power is provided within the data interface cable, and the distance between the camera and the controller/computer is very long. In order to avoid running multiple long cables in a production manufacturing environment, a power extraction module is incorporated into a light illuminator, in order to extract the power for the interface cable, and to generate the individual powers for the light illuminator and the camera. In cases where the interface standard does not provide integrated power, power can be injected to the cable and extracted from the light illumination module.