Illuminator Brightness Calibration Across Processing Apparatuses
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Solution Overview
Problem
Processing apparatuses experience differences in brightness between illuminators due to light source degradation or dirt accumulation, leading to inconsistent image quality when copying photographing and processing conditions between multiple machines.
Innovation Solution
A method is implemented where a sample image is stored with a first control value from a first processing apparatus, and comparative images are taken with varying control values in a second processing apparatus to identify a second control value minimizing brightness difference, allowing for correction of the illuminator's brightness to match the first apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If photographing conditions are copied from one processing apparatus to another, then processing efficiency is improved, but brightness inconsistency between apparatuses worsens due to light source degradation
Solution Approach 1:
The patent adjusts the control value parameter for illuminator brightness in the second processing apparatus to match the actual brightness level of the first apparatus. By comparing sample images captured at different control values and identifying the value that produces the most similar brightness characteristics, the system dynamically adapts the brightness parameter to compensate for hardware degradation, thereby maintaining consistent image quality across multiple apparatuses without requiring physical light source replacement.
2Device complexity
If light source degradation is allowed to occur naturally, then device complexity is reduced, but image quality consistency deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the brightness characteristics of the first processing apparatus are measured and stored as reference data. The second apparatus continuously compares its captured images against this reference and automatically adjusts its illuminator control value to maintain consistent brightness levels. This closed-loop feedback system ensures image quality consistency without requiring complex hardware interventions or frequent manual calibration.
3Measurement precision
If special test pieces are used to measure brightness, then measurement precision is improved, but device complexity and operation time increase
Solution Approach 1:
The patent enables the processing apparatus to perform its own brightness measurement and calibration using regular workpiece images rather than requiring external test pieces or specialized measurement equipment. The system captures images of actual workpieces, analyzes their brightness characteristics, and uses this information to self-adjust the illuminator control values. This self-service approach maintains measurement precision while avoiding the added complexity and operational overhead of specialized test equipment.
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 method reduces brightness differences between processing apparatuses, ensuring consistent image quality without replacing light sources or using special test pieces, thereby maintaining accurate identification of patterns and processing traces.
Implementation Method 1
photographing a workpiece by making reflected light of light applied from the illuminator to the workpiece incident on the imaging element via the objective lens
Implementation Method 2
a camera unit for photographing a workpiece, the camera unit having the illuminator
Data Source
AI summary
A method of adjusting the brightness of an illuminator in a processing apparatus includes, by a first processing apparatus, storing a sample image obtained by photographing a workpiece with a brightness specified by a first control value, together with the first control value, copying the sample image, the first control value and a processing condition to a second processing apparatus, by the second processing apparatus, storing a plurality of comparative images obtained by photographing the workpiece with brightnesses specified by a plurality of different control values, identifying a control value at a time of photographing a comparative image having a minimum difference in brightness from the sample image as a second control value, by comparing the sample image with the plurality of comparative images, and setting a difference between the first and second control values as a correction value of the control value of the second processing apparatus.