Illumination Apparatus with Integrated 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 to supply power and data to cameras and light illuminators, which increases installation and maintenance costs, and requires additional hardware and control mechanisms for multiple light sources, complicating wiring and illumination intensity adjustments.
Innovation Solution
A light illumination apparatus with integrated power and data streaming capabilities, using a power extraction module to convert and distribute power within the system, reducing the need for multiple cables by providing power directly to both the camera and illuminator through a single long cable, while maintaining efficient data communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power cables are used for the illuminator and camera, then each device receives adequate power, but the number of cables increases from one to three
Solution Approach 1:
The patent combines multiple power delivery functions into a single cable by implementing a power conversion module that accepts power from one source and converts it to multiple different voltages for different devices. This merging approach reduces the number of cables from three to one while maintaining reliable power delivery to both the illuminator and camera through voltage conversion.
Solution Approach 2:
The single cable is designed to serve multiple functions: delivering power to the power conversion module, which then distributes converted power to both the illuminator and camera. The cable becomes a universal power delivery mechanism that replaces multiple specialized cables, reducing complexity while maintaining functionality.
2Illumination intensity
If multiple light illuminators are added to achieve desired illumination intensity, then illumination requirements are met, but installation costs and system complexity increase
Solution Approach 1:
Instead of adding more illuminator units, the patent changes the power parameter (voltage) delivered to a single illuminator. The power conversion module converts input power to a higher voltage specifically suited for the illuminator, enabling it to operate at maximum intensity. This parameter change approach achieves high illumination output without the need for multiple illuminator units, reducing installation complexity and cost.
3Reliability
If different input voltages are provided for the illuminator and camera, then each device operates at optimal voltage, but additional power conversion hardware is required
Solution Approach 1:
The patent merges multiple power conversion functions into a single integrated power conversion module. This module accepts power at one voltage level and internally converts it to multiple different voltage levels required by different devices (illuminator and camera). By combining these conversion functions in one module rather than using separate converters for each device, the system reduces overall complexity while maintaining optimal voltage delivery to each component.
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 allows for flexible illumination configurations by providing power and data through a single long cable, enhancing the efficiency and reliability of machine vision systems.
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
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. The light illuminator may electrically and mechanically support secondary and/or supplemental light illuminators.