Image Processing for Reference-Count Defect Inspection
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Solution Overview
Problem
High-speed imaging in industrial product inspection can lead to decreased accuracy due to variations in the number of captured images, which can be less than or more than the desired number, affecting the effectiveness of methods like photometric stereo.
Innovation Solution
An image processing apparatus that includes a processor and memory to detect defects by ensuring the number of captured images matches a reference number, issuing warnings for deviations, and optionally deleting or adjusting images to maintain inspection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed imaging is performed to increase productivity, then the inspection speed is improved, but the number of captured images varies causing decreased inspection accuracy
Solution Approach 1:
The system counts the number of captured images and compares it against a predetermined reference number. When the count matches the reference number, inspection proceeds; otherwise, a warning is issued. This feedback mechanism ensures that high-speed imaging maintains the required image count for accurate photometric stereo inspection while preserving productivity benefits.
2Measurement precision
If the number of captured images is increased to improve inspection accuracy, then the measurement precision is improved, but the processing time and data volume increase
Solution Approach 1:
The system captures a predetermined number of images (the reference number) which is sufficient for accurate photometric stereo inspection without capturing excessive images. This partial action approach maintains inspection accuracy while avoiding unnecessary processing time and data volume associated with capturing more images than needed.
3Productivity
If continuous imaging is performed to maintain productivity, then the output rate is improved, but the synchronization between imaging and lighting may cause image quality issues
Solution Approach 1:
The system uses periodic lighting (strobe lighting) synchronized with the imaging process. The lighting unit emits light in periodic pulses that correspond to the capture of each image, ensuring consistent illumination and image quality during continuous high-speed imaging. This periodic action maintains both productivity and image quality reliability.
Data Source
AI summary
An image processing apparatus includes at least one processor and at least one memory that is in communication with the at least one processor. The at least one memory stores instructions for causing the at least one processor and the at least one memory to acquire captured images obtained by imaging an object; determine whether the number of the acquired captured images is a reference number for an inspection of the object; in a case where it is determined that the number of the acquired captured images is the reference number, detect a defect in the object based on the acquired captured images; and in a case where it is determined that the number of the acquired captured images is not the reference number, output a warning.