Non-contact Component Inspection Using Projected Light Patterns
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Solution Overview
Problem
Current inspection methods using white light non-contact systems are time-consuming and costly, requiring specialized training and expensive marker tapes for precise placement, which limits their efficiency and accessibility.
Innovation Solution
A non-contact inspection method that processes image data from projected light patterns onto components using a processing system to create model data, comparing it to nominal data to determine deviations and identify measurement data points, thereby reducing the need for manual identification and specialized training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If marker tapes are applied onto the surface of the object for inspection, then measurement precision is improved, but device complexity and operator training requirements increase
Solution Approach 1:
The patent removes the marker tape component from the inspection system entirely. Instead of requiring physical markers on the component surface, the system uses natural surface features and automated image processing to identify and measure component features, thereby eliminating the complexity of marker application while maintaining measurement precision
Solution Approach 2:
The inspection system uses the component's own surface features and geometry to enable measurement. The automated image processing algorithms identify features directly from the captured images without requiring external markers, allowing the component to serve its own measurement needs
2Measurement precision
If marker tapes are precisely placed on the object surface, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary automated processing of the captured images to identify surface features and establish measurement reference points before the actual measurement calculation. This preliminary feature identification eliminates the time-consuming manual marker placement step while ensuring precise measurement points are correctly identified
Solution Approach 2:
The patent replaces the mechanical process of manually placing marker tapes with an automated optical and computational system. Image processing algorithms automatically identify surface features and calculate measurement points, substituting the time-consuming mechanical marker application process with faster computational methods
3Measurement precision
If specialized training is provided to operators for marker tape application, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The inspection system is designed to be self-sufficient, using automated image processing and feature recognition algorithms that do not require specialized operator knowledge. The system automatically identifies surface features, establishes measurement references, and performs calculations, making the inspection process accessible to operators without extensive training while maintaining high measurement precision
4Measurement precision
If marker tapes are used for inspection, then measurement precision is improved, but loss of substance increases
Solution Approach 1:
The patent extracts and removes the marker tape consumable from the inspection process. By using automated image processing to identify natural surface features, the system eliminates the need for physical marker tapes, thereby eliminating the ongoing cost and waste associated with these consumables while maintaining measurement precision
Solution Approach 2:
Instead of using physical marker tapes, the system creates a digital copy or model of the component surface from captured images. This digital representation is then used for measurement and analysis, replacing the physical marker tape with an information-based approach that eliminates material consumption
Data Source
AI summary
An inspection method includes: receiving image data from a non-contact inspection system, the image data indicative of a plurality of captured images of light projected onto a component system comprising a component; processing the image data using a processing system to provide model data that models at least a portion of a surface of the component; comparing the model data to nominal data for a design model for the component using the processing system to determine a subset of the model data that is closest to the nominal data; identifying model data points in the subset of the model data based on identities of correlated nominal data points in the nominal data using the processing system to provide measurement data; and comparing the measurement data to design data for the design model for the component using the processing system to determine deviation between the measurement data and the design data.