Image Inspection Apparatus Circulation for Defect Differentiation
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Solution Overview
Problem
Current image inspection technologies face challenges in accurately distinguishing between defects caused by electrical noise, smudged reader surfaces, and actual image abnormalities, leading to difficulties in determining whether printed materials are normal or defective.
Innovation Solution
An image inspection apparatus that includes a storage for output image data, a conveyor for paper sheets, a reader for generating read image data, a determiner for comparing pixels between read and output data, and a controller to circulate the paper sheet for re-reading when mismatches are detected, allowing for precise determination of image normalcy by differentiating between reader abnormalities and image defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reading device is used to inspect printed materials, then defects can be detected, but it becomes difficult to distinguish between defects caused by electrical noise, smudged reader surfaces, and actual image abnormalities
Solution Approach 1:
The system performs preliminary actions by circulating the paper sheet multiple times through the reader before making a final determination. This allows the system to collect multiple readings of the same image data and distinguish between transient errors (electrical noise, smudges) and actual defects by comparing consistency across multiple measurements.
Solution Approach 2:
The system implements feedback by using the determiner to compare read image data with output image data, and when mismatches are detected, the controller circulates the paper sheet back through the reader for re-inspection. This feedback loop allows the system to refine its determination by comparing multiple readings and identifying consistent patterns that indicate actual defects versus transient errors.
2Measurement precision
If inspection is conducted with high accuracy to distinguish defects, then normal printed materials can be identified, but the inspection process becomes more complex and time-consuming
Solution Approach 1:
The system applies partial action by conducting multiple inspections only when necessary - specifically when the determiner detects a mismatch between read image data and output image data. Normal images that pass the first inspection are processed quickly, while only suspicious cases undergo additional circulation and re-inspection, balancing accuracy with efficiency.
Solution Approach 2:
The system performs a preliminary inspection pass through the reader to quickly identify obvious defects. Only images that fail this preliminary check are subjected to the more time-consuming multiple circulation and re-inspection process, allowing the system to maintain high accuracy while minimizing overall inspection time for normal materials.
3Reliability
If multiple inspections are conducted to differentiate defect causes, then determination accuracy improves, but the number of readings increases and reduces productivity
Solution Approach 1:
The system performs multiple inspections (circulations) only partially - specifically when the determiner detects mismatches that require further investigation. The controller intelligently decides when to circulate the paper sheet based on the need to differentiate between transient errors and actual defects, rather than universally applying multiple inspections to all images, thus maintaining productivity while improving reliability for critical cases.
Solution Approach 2:
The feedback mechanism allows the system to learn from each inspection result. When the determiner identifies mismatches, the controller initiates additional circulations and readings. The system uses this feedback to progressively refine its determination, increasing reliability only when and where needed, rather than uniformly increasing inspection counts for all images, thereby preserving overall productivity.
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 enables accurate inspection of printed materials, ensuring that only normal sheets are output while identifying and addressing issues caused by reader abnormalities or defects, thereby improving the reliability of image formation systems.
Implementation Method 1
a reader that reads the image formed on the paper sheet during conveyance being performed by the conveyor, and generates read image data
Data Source
AI summary
An image inspection apparatus includes: a storage that stores output image data used in forming an image on a paper sheet; a conveyor that conveys the paper sheet; a reader that reads the image during conveyance, and generates read image data; a determiner that compares pixels in the read image data with corresponding pixels in the output image data, and determines whether the read image data matches the output image data; a circulator that circulates the paper sheet, and returns the paper sheet to the reader; and a controller that controls the circulator to circulate the paper sheet and return the paper sheet to the reader when a mismatch is detected by the determiner, wherein the reader generates circulated read image data when the paper sheet is circulated and conveyed, and the determiner determines whether the image is normal or abnormal depending on the result of comparison.