Optical Inspection Tracking for In-Line Defect Imaging

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Solution Overview

Problem

Conventional methods for material testing in production or conveyor lines require objects to be stationary, limiting the number of inspections that can be performed within the available cycle time, especially in modern production systems with short cycle times.

Innovation Solution

The method involves moving the object and the optical inspection device synchronously, allowing images to be taken during the movement, utilizing both standstill and conveying times to increase the number of checking processes without extending standstill times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the object is kept stationary during inspection, then the inspection accuracy is improved, but the productivity deteriorates due to extended standstill times

Engineering Contradiction:

Improveinspection accuracyVSAvoidproductivity

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The inspection device is made movable to synchronize with the object's movement on the conveyor line, enabling inspection during motion rather than requiring the object to be stationary. This dynamic approach allows continuous production flow while performing multiple inspections at different locations along the object's path.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The inspection process is made continuous by moving the inspection device along with the object during conveying. Instead of interrupting production for stationary inspection, the system performs inspections continuously during the object's transport, utilizing the conveying time for multiple inspection operations.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If the object is moved during inspection, then the productivity is improved by utilizing conveying time, but the measurement precision deteriorates due to motion blur

Engineering Contradiction:

ImproveproductivityVSAvoidmeasurement precision

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The inspection device moves synchronously with the object at the same speed, creating a relatively stationary imaging condition. This dynamic synchronization eliminates motion blur by ensuring the inspection device and object maintain constant relative positions during image capture, enabling high-resolution imaging during motion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system replaces traditional stationary mechanical inspection with a dynamic optical inspection system that captures images during motion. High-speed imaging technology substitutes for mechanical stopping, allowing freeze-frame capture of moving objects without physical interruption of the production line.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple inspections are performed at standstill, then the inspection thoroughness is improved, but the cycle time deteriorates due to extended standstill times

Engineering Contradiction:

Improveinspection thoroughnessVSAvoidcycle time

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The system transitions from temporal dimension (multiple inspections sequentially at standstill) to spatial dimension (multiple inspections simultaneously during motion). By distributing inspection operations across different spatial locations along the conveyor path, the system performs multiple thorough inspections without extending the overall cycle time.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Multiple inspection operations are performed continuously during the object's conveying process rather than sequentially during standstill periods. The inspection device visits multiple predetermined locations along the object's path, performing comprehensive inspections while the object moves, thereby maintaining production flow and cycle time.

Inventive Principle:

Principle #20Continuity of useful action

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

This approach enables multiple inspections at 5 to 10 potential defect locations within the same cycle time, compared to the typical 1 or 2 inspections during standstill, without increasing cycle time, using high-resolution imaging to accurately detect and classify defects.

Implementation Method 1

at least one image (of the potential defect location) is taken by the inspection device at the potential defect location of the object

Methodology Applied

Scientific EffectOptical imaging: Photography

Data Source

PatentUS20250377309A1Method for material testing of an object in a production and/or conveyor line and inspection apparatus

Publication Date: 2025.12.11 ISRA VISION GMBH

AI summary

The invention relates to a method for material testing of an object (2) in a production and/or conveyor line and an inspection apparatus (10) adapted for carrying out the material testing. During material testing, the object (2) is transported along a conveying direction (4) in a conveying plane (3) of a production and/or conveyor device (1), an optical inspection device (11) is positioned at at least one previously identified potential defect location (30) of the object (2) and at least one image is taken by the optical inspection device (11) at the potential defect location (30) of the object (2, 102). The object (2) is moved during the material testing, and the optical inspection device (11) is moved along with the object (2), the at least one image being taken by the optical inspection device (11) during the movement of the object (2, 102) and optical inspection device (11).