Image Processing Apparatus for Real-Time Defect Detection
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Solution Overview
Problem
Existing image processing methods for detecting defects in a manufacturing line are not capable of providing real-time inspection results, as they require processing images of multiple objects sequentially, leading to slower response times and reduced efficiency.
Innovation Solution
An image processing apparatus and method that acquires work inspection images and reference images for each object, generates aligned images by arranging the reference images around the inspection images, and performs singular portion detection using peripheral vision and involuntary eye movement processing, allowing for rapid detection of defects in individual objects without the need for extensive image processing of multiple objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If images of multiple objects are processed sequentially to detect defects, then defect detection accuracy is improved, but inspection speed deteriorates
Solution Approach 1:
The patent applies preliminary action by generating aligned images in advance and performing singular portion detection on these pre-processed images. The system creates aligned images by arranging reference images around inspection images before the actual defect detection process, which enables faster real-time inspection without compromising accuracy
Solution Approach 2:
The patent segments the inspection process into distinct stages: image acquisition, aligned image generation, and singular portion detection. By dividing the workflow and processing each object's images independently through these segmented steps, the system achieves both high detection accuracy and real-time inspection speed
2Reliability
If images of multiple objects are acquired and processed to inspect one object, then detection reliability is improved, but response time deteriorates
Solution Approach 1:
The system performs preliminary actions by pre-generating aligned images and preparing reference images before actual inspection is needed. This allows the inspection of each object to be completed independently and rapidly, improving response time while maintaining detection reliability through the use of pre-processed reference data
Solution Approach 2:
The patent uses copying by creating aligned images that replicate the structure and features of reference images. These copied and arranged images serve as reliable comparison data for defect detection, enabling fast inspection without requiring access to multiple original objects
3Reliability
If sequential image processing of multiple objects is performed, then comprehensive inspection is improved, but real-time output capability deteriorates
Solution Approach 1:
The patent segments the inspection process to handle each object independently through distinct stages: acquiring the inspection image, generating its aligned image, and performing singular portion detection. This segmentation enables comprehensive inspection of each object while achieving real-time output capability
Solution Approach 2:
The system performs preliminary actions by pre-generating aligned images and preparing reference data before inspection is required. This allows comprehensive inspection to be completed in real-time by using pre-processed images that capture all necessary inspection information
Data Source
AI summary
An image processing apparatus acquires a work inspection image by image-taking one inspection object, acquires a work reference image that is different from the work inspection image, generates an aligned image by arranging the work reference image at the periphery of the work inspection image and subjects the aligned image to singular portion detection processing to detect a singular portion in the aligned image. The singular portion detection processing is performed on a first work inspection image obtained by image-taking a first inspection object, subsequently the singular portion detection processing is performed on a second work inspection image obtained by image-taking, after the first inspection object, a second inspection object, and subsequently the singular portion detection processing is performed on a third work inspection image obtained by image-taking, after the second inspection object, a third inspection object.