Multi-Camera Inspection Image Linking on Moving Conveyors
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Solution Overview
Problem
Existing product inspection systems struggle to accurately track and compare multiple images of a product instance as it moves through different phases of a production process, leading to confusion and incorrect inspection results due to conveyor movement and potential product removal.
Innovation Solution
A vision-based system with multiple cameras positioned along a conveyor, using incremental encoders and machine-readable codes to associate images of the same product instance, enabling accurate comparison and automated quality control by determining differences in camera fields of view and conveyor positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple cameras are positioned along the conveyor to capture images at different phases, then inspection coverage is improved, but image association accuracy deteriorates due to conveyor movement and product removal
Solution Approach 1:
The patent introduces an intermediary association mechanism that uses product identifiers (barcodes, RFID tags) and conveyor position data (encoder readings) as mediating elements to link images from multiple cameras. This intermediary system resolves the ambiguity of which images belong to which product instance by creating a unique association key for each product-camera-position combination, thereby maintaining measurement precision while enabling multi-camera inspection coverage.
Solution Approach 2:
The system implements feedback through continuous monitoring of conveyor position via encoders and real-time updating of image associations. As the conveyor moves and products are removed, the system receives feedback about current position and product presence, dynamically adjusting which images are associated with which product instances. This feedback loop ensures accurate image association despite ongoing conveyor movement and product removal.
2Manufacturing precision
If images are captured continuously as products move on the conveyor, then inspection thoroughness is improved, but tracking reliability deteriorates due to product removal and conveyor interruptions
Solution Approach 1:
The patent applies preliminary action by capturing and storing product identifiers (barcodes, RFID tags) and initial position data before products are removed from the conveyor or interruptions occur. This preliminary capture of identification information creates a persistent reference that allows the system to maintain tracking and associate subsequent images even when products are temporarily out of view or the conveyor stops, thereby preserving tracking reliability while enabling thorough inspection.
Solution Approach 2:
The system implements beforehand cushioning by maintaining a buffer of association data including product identifiers, captured images, and position information for products that may be removed or cause interruptions. This buffer acts as a cushion that prevents tracking failures when products are removed from the line or when conveyor interruptions occur, allowing the system to recover and continue accurate tracking without losing inspection data.
3Measurement precision
If multiple images of the same product instance are associated and compared, then quality control accuracy is improved, but system complexity increases due to image management and association tracking
Solution Approach 1:
The patent applies segmentation by dividing the image management system into modular components: image capture modules, association modules (using product identifiers and position data), comparison modules, and decision modules. Each module handles a specific aspect of the inspection process independently. This segmentation reduces system complexity by making each component manageable and interchangeable, while still enabling accurate quality control through the coordinated comparison of multiple associated images.
Data Source
AI summary
A vision-based product inspection system captures multiple images of each of multiple individual instances of a product as each instance passes through various phases of a production process. The system includes multiple cameras with each camera situated at a known location along a moving conveyor, conveyor belt, production line, or assembly line that moves instances of the product through various phases of the production process. Each camera can be associated with a known location along the conveyor and each image can be associated with a value representing the position of the conveyor as it moves product. Based on each camera's location and the values representing the conveyor's position, a sequence of images can be accumulated representing the progression of any single instance of a product as it moves through the production process. Automated quality control inspection can be performed by comparing or analyzing images in the sequence.