Image Capture Condition Adjustment for Uniform Brightness Inspection
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Solution Overview
Problem
Existing image capture techniques for inspecting complex three-dimensional objects like vehicle bodies require manual checking of binarized images for each of the 1,000 captured images, which is impractical, and methods for uniform exposure time or reflectance control are not applicable due to the changing brightness distribution.
Innovation Solution
An image capture condition adjustment device and method that adjusts exposure time and camera gain to ensure uniform brightness across multiple images, using one-dimensional histograms to display and analyze brightness distribution, allowing for automated adjustment without manual inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual checking of binarized images is performed for each captured image, then image capture condition optimization can be verified, but the inspection process becomes extremely time-consuming and impractical for about 1,000 images
Solution Approach 1:
The patent creates a composite image by synthesizing multiple captured images into a single composite representation. This composite image serves as a copy that represents the overall quality of all captured images, allowing verification to be performed on this single composite image rather than manually checking each of the 1,000 individual binarized images, thus dramatically reducing inspection time while maintaining verification accuracy
Solution Approach 2:
The patent merges multiple captured images into a single composite image that aggregates brightness distribution information from all images. By combining the verification task into this single composite representation, the system eliminates the need to individually examine each binarized image, resolving the contradiction between thorough verification and time efficiency
2Manufacturing precision
If exposure time is controlled based on substrate reflectance for uniform objects, then image capture conditions can be optimized, but this approach cannot be applied to complex three-dimensional objects like vehicle bodies where brightness distribution changes continuously
Solution Approach 1:
The patent dynamically adjusts exposure time for each captured image based on the actual brightness distribution measured in that specific image. Rather than using a fixed exposure time suitable for uniform substrates, the system adapts the exposure time to match the varying brightness conditions of complex three-dimensional objects like vehicle bodies, enabling the optimization approach to be universally applied across different object types
Solution Approach 2:
The patent changes the exposure time parameter for each image capture based on the measured brightness distribution of the specific object being captured. This dynamic parameter adjustment allows the system to optimize image capture conditions for uniform substrates and adapt to the continuously varying brightness distributions of complex three-dimensional objects, achieving versatility across different object geometries
3Stability of the object's composition
If image capture conditions are optimized for each individual image, then brightness distribution uniformity can be achieved, but the complexity of managing and verifying conditions for about 1,000 images increases significantly
Solution Approach 1:
The patent creates a composite image that serves as a simplified representation of all captured images' brightness distributions. This composite copy allows the system to achieve and verify brightness uniformity across all images without the complexity of individually managing 1,000 separate condition sets, as the composite image provides an aggregated view of overall brightness distribution
Solution Approach 2:
The patent implements a universal image capture condition adjustment that applies to all captured images simultaneously through the composite image approach. Rather than managing separate optimization parameters for each of the 1,000 images, the system uses a single composite-based adjustment mechanism that universally improves brightness distribution uniformity across the entire image set, significantly reducing management complexity
Data Source
AI summary
An image capture condition adjustment device (3) includes an acquisition means (31) that acquires a plurality of captured images obtained by capturing a workpiece (100) illuminated by an illumination device (1) with a camera (2) while moving at least one of the illumination device or the camera relative to the workpiece, and an adjustment means (36) that adjusts an image capture condition for the camera (2) in such a manner that distribution of brightness of an image is uniform for each of the plurality of captured images acquired.