Image Processing Device Positional Alignment for Inspection Consistency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing image processing devices face challenges in maintaining consistent inspection target images due to changes in optical conditions during operation, requiring time-consuming recalibration of installation and optical conditions to reproduce the ideal inspection target image.
Innovation Solution
An image processing device that includes an imaging unit, a storage unit for reference images, and a calculation unit to specify the positional relationship between the inspection object in the inspection target image and the reference image, allowing for the generation of inspection target images with the inspection object at the same position, even when optical conditions change, by adjusting positional information, zoom magnification, brightness, and posture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the same optical conditions and installation conditions as the desk test are reproduced in the operation environment, then the inspection target image should be the same as the desk test image, but the inspection target image may still differ due to strict environmental differences between desk test and actual operation
Solution Approach 1:
The system performs preliminary calibration in the desk test environment to establish reference data including camera parameters, illumination conditions, and inspection standards. This reference data is stored and automatically applied during operation to maintain image consistency despite environmental variations.
Solution Approach 2:
The system continuously monitors actual operation conditions and compares them against the reference data from desk test. When deviations are detected in optical conditions or installation parameters, the system automatically adjusts parameters to maintain image consistency with the reference standard.
2Measurement precision
If optical conditions change during the operation phase, then image quality may change, but recalibrating to search for ideal conditions requires time and effort
Solution Approach 1:
The system performs automatic self-calibration by comparing current operation images with stored reference images. The calculation unit automatically detects parameter changes and adjusts optical conditions without requiring manual intervention or time-consuming manual recalibration procedures.
Solution Approach 2:
All calibration parameters and reference data are established in advance during desk test. When operation conditions change, the system refers to these pre-established references and automatically adjusts, avoiding the need for time-consuming recalibration and maintaining rapid response to environmental changes.
3Measurement precision
If manual recalibration is performed to maintain inspection target image consistency, then image quality can be restored, but operational efficiency is reduced due to time and effort requirements
Solution Approach 1:
The system implements continuous automatic monitoring and adjustment of optical conditions by comparing real-time images with reference standards. This closed-loop feedback mechanism maintains image consistency without interrupting production flow, thereby preserving operational efficiency while ensuring quality.
Solution Approach 2:
The inspection system performs automatic self-calibration and self-adjustment of optical parameters without requiring manual intervention. The calculation unit autonomously detects deviations and corrects them, eliminating the time and effort previously needed for manual recalibration and maintaining high operational efficiency.
Data Source
AI summary
An image processing device includes an imaging unit generating an inspection target image, a storage unit storing a reference image obtained by capturing an inspection object in advance, and a calculation unit specifying a positional relationship between an inspection object included in the inspection target image generated during operation and the inspection object included in the reference image, and calculates a generation condition of the inspection target image during operation such that the inspection object included in the inspection target image generated during operation and the inspection object included in the reference image are at substantially the same position. The generation condition includes positional information of an output region in which the inspection object is able to be output at substantially the same position as the reference image. The imaging unit generates an inspection target image corresponding to the output region of the positional information during operation.