Image Inspection Device Multi-Angle Defect Detection
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Solution Overview
Problem
Manual inspection of blade wheels with complex contours is inefficient and unreliable due to the difficulty in observing all possible defects from a single angle, requiring extensive time and multiple angles for thorough examination.
Innovation Solution
An image inspection device comprising a rotating platform, two image capturing devices (top-view and lateral-view), a storage unit, and a processing unit that captures and compares images of the workpiece from different angles with pre-stored standard images to determine defects, allowing for efficient inspection by rotating the workpiece to specific angles based on its top-view image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection is performed from one angle, then the inspection process is simple, but defects on complex contour surfaces cannot be fully detected
Solution Approach 1:
The patent transitions from single-angle inspection to multi-angle inspection by rotating the workpiece to capture images from different perspectives. The processing unit calculates rotation angles based on surface normal vectors and contour features, enabling the inspection system to view complex surfaces from multiple dimensions and detect defects that would be invisible from a single angle.
Solution Approach 2:
The inspection system dynamically rotates the workpiece to specific angles calculated from the top-view image analysis. Rather than static single-angle inspection, the system adapts the inspection angles based on the actual contour features detected, making the inspection process dynamic and tailored to each workpiece geometry.
2Reliability
If manual inspection is performed from multiple angles, then defect detection reliability improves, but inspection time increases significantly
Solution Approach 1:
The system first captures a top-view image and performs preliminary analysis to identify contour features and calculate optimal rotation angles before conducting the actual multi-angle inspection. This preliminary action allows the system to plan the inspection path in advance, avoiding unnecessary rotations and focusing only on critical angles where defects are most likely to be detected.
Solution Approach 2:
The system captures a top-view image that serves as a reference copy to analyze contour features and determine the optimal inspection angles. This top-view copy is used to calculate the rotation angles without requiring physical manipulation or additional imaging at those angles, reducing the overall inspection time while maintaining detection reliability.
3Productivity
If automated image capture and comparison is implemented, then inspection efficiency improves, but device complexity increases
Solution Approach 1:
The processing unit performs multiple functions: it analyzes top-view images to extract contour features, calculates optimal rotation angles, controls the rotating platform positioning, and compares lateral-view images with reference images. This multi-functional approach consolidates what could be separate complex subsystems into a single intelligent processing unit, improving efficiency without proportionally increasing overall system complexity.
Solution Approach 2:
The top-view image serves as an intermediary that bridges the gap between the workpiece geometry and the inspection planning. By analyzing this intermediate representation, the system can determine optimal inspection angles without requiring complex direct measurement or physical probing of the three-dimensional surface, simplifying the overall system architecture.
Data Source
AI summary
An image inspection device includes a rotating platform configured to carry a workpiece; a first image capturing device configured to capture a top-view image of the workpiece; a second image capturing device configured to capture a lateral-view image of the workpiece; a storage unit configured to pre-store a plurality of lateral-view images of a standard workpiece from different angles; and a processing unit. The processing unit controls the rotating platform to rotate the workpiece to a first angle and a second angle according to the top-view image. The processing unit is configured to generate a first comparison result and a second comparison result by comparing the lateral-view images of the workpiece with lateral-view images of the standard workpiece from, respectively, the first angle and the second angle, and determine whether the workpiece has a defect according to the first comparison result and the second comparison result.