In-flight 3D Inspector for Automated Defect Detection
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Solution Overview
Problem
Human visual inspection of objects like tree nuts and tablets is time-consuming, costly, and inconsistent, necessitating a faster, more accurate, and cost-effective automated defect detection solution.
Innovation Solution
An in-flight 3D inspector system comprising cameras, a light source, a trigger, and a computer system that captures multiple images of a sample in flight, generating a three-dimensional image to detect defects without surface contact, allowing for precise defect characterization and quality grading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human inspection is used to detect defects, then inspection accuracy can be maintained through human judgment, but inspection time and cost increase significantly
Solution Approach 1:
The patent replaces the human visual inspection system with an automated optical inspection system using multiple cameras and light sources. The system captures images of samples in-flight and processes them through computer algorithms to detect defects, eliminating the need for human inspectors while maintaining or improving detection accuracy and significantly reducing inspection time.
Solution Approach 2:
The system creates multiple digital copies (images) of the physical sample from different angles and perspectives. These image copies are then processed by computer algorithms to detect defects, replacing the need for direct human observation while preserving the ability to accurately identify defects through digital analysis.
2Adaptability or versatility
If human inspection is used to generate quality reports, then subjective judgment can be applied, but consistency between different inspectors decreases
Solution Approach 1:
The patent replaces human judgment with automated computer-based analysis algorithms that process the captured images. These algorithms apply consistent criteria for defect detection and quality grading, eliminating variability between different inspectors while maintaining the ability to adapt to different quality standards through software configuration.
3Productivity
If automated inspection systems are implemented, then inspection speed and cost-effectiveness improve, but system complexity increases
Solution Approach 1:
The inspection system is divided into distinct functional modules: multiple cameras for image capture, light sources for illumination, a trigger mechanism for synchronization, and a computer system for image processing. This segmentation allows each component to be optimized independently while working together to achieve high-speed automated inspection.
Solution Approach 2:
The system performs preliminary actions by capturing multiple images of the sample in-flight before any analysis occurs. The trigger mechanism pre-synchronizes the cameras and light sources, and the system prepares the imaging sequence in advance, enabling rapid processing and reducing overall inspection time.
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
The system enables rapid, accurate, and repeatable defect detection, reducing human error and costs, while providing high-quality 3D images for consistent quality reporting and sorting.
Implementation Method 1
The light source is adapted to illuminate the sample when it travels through the focal plane
Implementation Method 2
The trigger detects the presence of a sample and generates a trigger signal
Data Source
AI summary
An in-flight 3D inspector includes a sample input funnel, a sample chute, a trigger, a plurality of cameras, a light source and storage device. A sample is placed in the sample input funnel and is caused to travel down the sample chute. The trigger is located on the sample chute and detects when the sample passes the trigger. In response to detecting the passing of the sample, the trigger outputs a trigger signal that indicates when the sample will pass through a focal plane on which all the plurality of cameras are focused. In response to the trigger signal, the sample is illuminated by the light source and the plurality of cameras capture an image of the sample as the sample passes through the focal plane. The captured images are stored on the storage device and used to generate a 3D image of the sample.