Inline Image-Based Operation Checks for Article Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing article inspection apparatuses require manual operation checks, leading to increased downtime, decreased production efficiency, and inability to accurately assess product quality during normal operation due to transitioning to inspection stop states.
Innovation Solution
An article inspection apparatus that performs operation checks in parallel with normal operation using an image processing unit, determination unit, and display unit, generating operation check images to assess the functionality of these units during normal operation, allowing for continuous inspection without stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation checks are performed by transitioning to inspection stop states, then the functionality of inspection units can be assessed, but downtime increases and production efficiency decreases
Solution Approach 1:
The patent enables operation checks to be performed continuously during normal inspection operations without stopping the production line. The inspection units process both actual inspection images and operation check images in sequence, maintaining continuous operational status while periodically assessing detection unit functionality through generated operation check images.
Solution Approach 2:
The patent creates operation check images as synthetic copies that simulate defective articles. These copied images are generated by the operation check image generation unit and used to verify detection unit functionality without requiring actual defective physical samples, thereby eliminating the need to stop production for manual operation checks.
2Reliability
If manual operation checks are performed by flowing physical samples, then detection unit functionality can be verified, but work time not converted into data increases and operation check efficiency decreases
Solution Approach 1:
The patent replaces the mechanical process of physically transporting and manually handling operation check samples with an automated digital image generation system. The operation check image generation unit automatically creates operation check images from inspection images, and the control unit automatically feeds these images to the detection unit, eliminating manual intervention and physical sample handling.
Solution Approach 2:
The inspection apparatus performs self-verification by generating its own operation check images internally and automatically processing them through the detection units. The system uses its own imaging and processing resources to conduct operation checks without requiring external physical samples or manual operation, enabling continuous autonomous functionality assessment.
3Measurement precision
If inspection stops are implemented for operation checks, then accurate detection of product quality variation can be performed, but downtime increases and production efficiency is reduced
Solution Approach 1:
The patent implements periodic operation checks during continuous production by generating operation check images at predetermined intervals. The control unit determines timing for operation checks and processes operation check images periodically alongside actual inspection images, maintaining both production continuity and regular functionality verification without requiring inspection stops.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The article inspection apparatus includes an image processing unit (33) that performs an image process with respect to an imaging data (Dpx) of an article (P) and outputs determination data, a determination unit (34) that determines a quality state of the article (P) based on the determination data, an operation check image generation unit (53) that generates an image including an NG feature image (Cn) in which the quality state is determined to be defective as an operation check image (Dpc) used in an operation check processing unit (54) based on an inspection image during a driving operation, and an operation check processing unit (54) that executes an operation check process using the predetermined image processing algorithm in parallel with an operation of the image processing unit (33) during the driving operation, and determines whether the operations of the image processing unit (33) and the determination unit (34) are normal.