Industrial Camera Optical Calculation for Simplified Installation
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Solution Overview
Problem
The installation of industrial cameras for image inspection is difficult and cumbersome, requiring precise positioning and adjustment of lenses and cameras, even after initial setup changes.
Innovation Solution
An industrial camera system that includes an imaging unit, distance measurement, storage, and calculation units to automatically determine optical conditions based on user inputs and camera parameters, allowing for simplified installation and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the camera is installed at a precise position with accurate optical conditions, then the inspection image quality is improved, but the installation complexity and difficulty increase
Solution Approach 1:
The system performs preliminary calculations of optimal installation positions and optical conditions before actual installation. The calculation unit computes the required optical conditions (zoom magnification, focus distance) based on pre-stored camera parameters and user-specified inspection requirements, allowing installers to simply position the camera roughly and then adjust based on calculated values rather than performing complex manual optimization during installation
Solution Approach 2:
The patent replaces manual mechanical adjustment processes with automated calculation and control. Instead of requiring installers to manually adjust lens positions, focal lengths, and zoom levels to achieve optimal imaging, the system automatically calculates the required optical conditions and controls the lens unit to achieve them, substituting mechanical trial-and-error adjustment with computational determination
2Manufacturing precision
If the lens and camera are reselected and adjusted when inspection conditions change, then the inspection accuracy is improved, but the operation time and complexity increase
Solution Approach 1:
The system enables dynamic adaptation to changing inspection conditions through automated recalculation. When inspection requirements change (different inspection objects, different required magnification), the calculation unit automatically recomputes the optimal optical conditions based on current camera parameters and new requirements, allowing rapid reconfiguration without manual lens selection or physical repositioning
Solution Approach 2:
The system incorporates feedback loops where the calculation unit continuously monitors inspection requirements and adjusts optical conditions accordingly. The interface unit receives user input about inspection needs, the calculation unit processes this information against stored camera parameters, and automatically determines the required zoom magnification and focus settings, creating a closed-loop system that adapts to changing conditions without manual intervention
3Measurement precision
If the camera installation position is adjusted to match calculated optical conditions, then the required specification is achieved, but the installation ease deteriorates
Solution Approach 1:
The system enables self-service installation by automatically determining optimal positions and conditions. The calculation unit uses pre-stored camera parameters (focal length, sensor size) and user-specified requirements to autonomously calculate the correct installation position and optical conditions, eliminating the need for installers to perform complex measurements or calculations themselves. The camera system essentially installs itself by automatically adjusting lens parameters to match calculated values
Data Source
AI summary
Installation of an industrial camera is simplified. An industrial camera includes an imaging unit that captures an inspection object to generate an inspection target image, a distance measurement unit that measures an installation distance that is a distance to the inspection object, a storage unit that stores a camera parameter of the imaging unit, an interface unit that is able to receive an input of a size of a field of view or a pixel resolution as a required specification from a user, and a calculation unit that automatically calculates an optical condition necessary for realizing the required specification based on the installation distance measured by the distance measurement unit, the camera parameter stored in the storage unit, and the input required specification.