Multi-Camera Inspection Alignment Using Removable Turntable References
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Solution Overview
Problem
Existing inspection systems struggle to align images of objects with large positional variations around a vertical axis, as they lose information about the object's position in the third dimension, leading to difficulties in comparing reference and test images.
Innovation Solution
A testing system using a motor-driven turntable that captures multiple reference images of the object in different rotational positions, which are stored and used to align test images using image warping techniques, ensuring accurate comparison and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single reference image is used for comparison, then the inspection system is simple to operate, but it cannot handle objects with large positional variations around the vertical axis
Solution Approach 1:
The system performs preliminary action by capturing multiple reference images of the reference object at different rotational positions before actual inspection begins. These pre-captured reference images are stored in a reference image library, enabling the system to handle objects with various positional variations without requiring real-time adjustments during inspection.
Solution Approach 2:
The reference image is segmented into multiple rotational positions, creating a library of reference images captured at different angles. This segmentation allows the inspection system to select and compare against the most appropriate reference image based on the object's actual position, thereby handling large positional variations effectively.
2Measurement precision
If multiple reference images are captured at different rotational positions, then alignment accuracy for objects with large positional variations is improved, but the time required for reference image capture increases
Solution Approach 1:
Multiple reference images are captured in advance during a setup phase rather than during production inspection. This preliminary action ensures high measurement precision for objects with large positional variations while minimizing time loss during actual manufacturing, as the reference library is prepared once and reused for multiple inspections.
3Ease of manufacture
If a turntable is permanently integrated into the inspection system, then reference images can be easily captured in multiple positions, but the system complexity and space requirements increase
Solution Approach 1:
The turntable is designed as a temporary, removable component rather than a permanent fixed installation. It can be positioned in the inspection area when reference images need to be captured and then removed or stored when not in use. This dynamic approach maintains ease of manufacture for capturing multi-position reference images while avoiding the complexity of permanent integration into the inspection system.
Data Source
Figure 1
AI summary
In order to produce a test system for testing, by means of a multi-camera system, objects that are to be tested from all sides and have a position variance about a vertical axis, according to the invention, a motor-driven rotary plate which is rotatable about an axis of rotation can be temporarily introduced into an already existing test area of the test system. A reference object for the matching objects to be tested is placed by its standing surface on the rotary plate. By means of the image capture devices already present in the test area, a plurality of reference images of the reference object are captured in different rotary positions of the rotary plate and are stored in a processing unit for the images. After the reference images have been captured, the rotary plate is removed from the test area, and the control operation of the test system for capturing test images of the objects to be tested can begin.