Image Sensor Illumination Module Lifetime Prediction
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Solution Overview
Problem
Conventional smart cameras lack the ability to individually monitor the deterioration of illumination modules, leading to potential malfunctions and increased maintenance costs.
Innovation Solution
An image sensor system that includes an illumination module with a light emitting part and a nonvolatile memory, where the processing part stores and retrieves data to predict the lifetime of the light emitting part based on electric parameter values and cumulative power-on time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the illumination module is continuously used to provide stable inspection, then the inspection function is maintained, but the light quantity deteriorates over time causing brightness changes and potential malfunctions
Solution Approach 1:
The patent applies preliminary action by storing operation data (cumulative power-on time and electric parameter values) in the memory before deterioration occurs, and using this stored data to predict the remaining lifetime of the light emitting part. This allows the system to proactively monitor and predict illumination module degradation, enabling timely maintenance before actual malfunction occurs, thus maintaining inspection stability while managing the illumination module's operational duration.
2Measurement precision
If a PD (Photodiode) is installed on the substrate of the illumination module to monitor light quantity, then deterioration can be monitored, but cost increases and substrate area expands
Solution Approach 1:
The patent extracts the monitoring function from the illumination module substrate by using the image sensor to capture images of a reference chart illuminated by the light emitting part. Instead of installing a PD on the substrate, the system uses the existing image sensor and processing capabilities to indirectly measure light quantity by analyzing the brightness of captured reference images, thereby avoiding increased substrate complexity and cost.
Solution Approach 2:
The patent introduces a reference chart as an intermediary object between the illumination module and the measurement system. By capturing images of this reference chart with the image sensor, the system can indirectly measure the light quantity of the illumination module without requiring direct sensors on the illumination substrate, thus avoiding the complexity and cost of installing PDs while achieving accurate monitoring.
3Adaptability or versatility
If modular structure smart camera is introduced with freely combinable modules, then user needs are met and product differentiation is achieved, but individual module deterioration monitoring becomes more difficult
Solution Approach 1:
The patent applies self-service by having each illumination module include its own memory for storing operation data and identification information. Each module is self-sufficient in terms of data storage, and the image sensor system automatically retrieves and uses this data for lifetime prediction without requiring external monitoring equipment. This maintains modular versatility while enabling automatic individual module monitoring through the module's own embedded resources.
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
Enables accurate monitoring and prediction of illumination module deterioration, allowing for timely inspection and replacement, thereby preventing malfunctions and reducing maintenance costs.
Implementation Method 1
The illumination module includes a light emitting part for emitting light
Data Source
Figure 1
Figure 2(A)~3
AI summary
An image sensor system includes an image sensor and a prediction part. The image sensor includes an illumination module and a processing part. The illumination module includes a light emitting part for emitting light and a nonvolatile memory. The processing part stores a first data and a second data in the memory. The first data includes an electric parameter value when the light emitting part is applied with a power and a cumulative power-on time obtained by accumulating a time when the light emitting part is applied with the power. The second data includes a value obtained by multiplying the electric parameter value when the light emitting part is applied with the power by the cumulative power-on time. The prediction part obtains the first data or the second data from the memory and predicts a lifetime of the light emitting part based on the first data or the second data.