Optical Inspection Device with Light-Absorbing Cavity
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Solution Overview
Problem
Current optical inspection methods for products and blanks are inefficient due to long inspection times, high costs, and limitations in analyzing all components and their arrangements, as they require complex movement and alignment of optical sensors and image analysis technologies.
Innovation Solution
An inspection device with a box-like body coated to minimize light reflection, equipped with a high-resolution video camera and lighting assembly, and a control unit for storing reference images, allowing for fast and versatile optical control of elements with reduced programming and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensors are moved or repositioned for correct analysis of all parts, then inspection completeness is improved, but inspection time and device complexity increase
Solution Approach 1:
The patent transitions from a 2D fixed-focus sensor to a 3D movable sensor system that can change its position and focus distance. The sensor is mounted on a movable support that allows it to approach different parts of the workpiece at varying distances, enabling high-resolution inspection of multiple surfaces without requiring complex multi-sensor arrangements.
Solution Approach 2:
The inspection system employs dynamic elements including a movable sensor support that can reposition the sensor, a rotatable support that can orient the sensor at different angles, and a movable mirror that can redirect light paths. These dynamic components allow a single sensor to inspect multiple areas of the workpiece by changing its position and orientation during the inspection process.
2Device complexity
If fixed-focus optical sensors are used, then device complexity is reduced, but inspection capability is limited to predefined distances
Solution Approach 1:
The patent employs dynamic elements including a movable sensor support that can reposition the sensor, a rotatable support that can orient the sensor at different angles, and a movable mirror that can redirect light paths. These dynamic components allow a single sensor to inspect multiple areas of the workpiece by changing its position and orientation during the inspection process.
Solution Approach 2:
The single optical sensor is designed to perform multiple inspection functions by changing its position and orientation. The same sensor can inspect different surfaces, detect various defects, and analyze different areas of the workpiece without requiring multiple specialized sensors, thereby achieving multi-functionality with a single device.
3Measurement precision
If image analysis technology uses preset graphic markings as reference, then measurement accuracy is improved, but programming time and operational complexity increase
Solution Approach 1:
The system automatically captures reference images of the workpiece during the inspection process and uses these self-generated images as the basis for defect detection. The computer compares the captured images against the reference images it has stored, eliminating the need for manual presetting of graphic markings and reducing programming complexity while maintaining measurement accuracy.
4Measurement precision
If multiple high-resolution sensors are used to inspect all components, then inspection completeness is improved, but device cost and complexity increase
Solution Approach 1:
The single optical sensor is designed to perform multiple inspection functions by changing its position and orientation. The same sensor can inspect different surfaces, detect various defects, and analyze different areas of the workpiece without requiring multiple specialized sensors, thereby achieving multi-functionality with a single device.
Solution Approach 2:
The inspection system employs dynamic elements including a movable sensor support that can reposition the sensor, a rotatable support that can orient the sensor at different angles, and a movable mirror that can redirect light paths. These dynamic components allow a single sensor to inspect multiple areas of the workpiece by changing its position and orientation during the inspection process.
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 device enables rapid and cost-effective inspection of multiple parameters, simplifying programming and reducing the number of components, while ensuring high-quality image acquisition and efficient data processing, thus improving inspection speed and lowering overall costs.
Implementation Method 1
The internal surfaces that delimit it are coated with an opaque pigmentation which minimizes the light reflection coefficient
Implementation Method 2
at least one lighting assembly, arranged inside said cavity of said box-like body and proximate to the lens of the at least one video camera, comprising distributed sources and at least one diffusion screen
Data Source
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AI summary
An inspection device (1) for the optical control of elements such as a product, a blank, and the like, which comprises: a box-like body (2) which forms an internal cavity (6) in which the internal surfaces that delimit it are coated with an opaque pigmentation which minimizes the light reflection coefficient; at least one video camera (8), arranged within the cavity (6), having a sensor with a diagonal having a length of no less than 9 mm, a resolution of no less than 10 megapixels, provided with a digital interface; at least one lighting assembly (9), arranged inside the cavity (6) and proximate to the lens of the at least one video camera (8), comprising distributed sources and at least one diffusion screen; at least one opening (10), arranged along the box-like body (2), for the access of at least one element and its delivery to respective supporting elements (11) in order to keep the at least one element facing the at least one video camera (8) and the lighting assembly (9); at least one control and management unit, provided with an interface for communication with the at least one video camera (8) and with means for storing data containing reference images of an ideal element.