Motor Vehicle Lamp Reflector Reflectance Validation by Optical Imaging
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Solution Overview
Problem
Current reflector quality control in motor vehicle lamps is manual, prone to errors, and costly, with accuracy dependent on the operator, leading to potential rejection of entire lamps due to non-compliant reflectors.
Innovation Solution
An automated quality control system using a light source, image capturing apparatus, and processing device to determine reflectance and luminance, with a calibration method to establish a proportionality parameter for accurate, automatic validation of reflector quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual quality control by operators is used, then implementation costs and times are significant, but the system can detect quality issues
Solution Approach 1:
The patent replaces the manual mechanical inspection system with an automated optical measurement system. The reflector is illuminated by a light source and captured by an imaging device, with image processing algorithms automatically determining reflectance values. This substitution eliminates human operators from the quality control process, reducing implementation costs and times while maintaining or improving measurement precision through objective, repeatable optical measurements.
2Productivity
If automated quality control is implemented, then production costs are reduced, but measurement accuracy must be maintained
Solution Approach 1:
The patent transforms the quality control measurement from subjective visual assessment to objective quantitative reflectance measurement. By illuminating the reflector with a known light source and capturing the reflected light with an imaging device, the system calculates reflectance values through image processing. This parameter change from qualitative to quantitative measurement enables automated processing while maintaining high measurement precision through mathematical calculations based on light physics.
Solution Approach 2:
The patent creates a digital copy of the reflector's optical properties through imaging. The imaging device captures the reflected light pattern, and image processing algorithms generate a digital representation of the reflector's reflectance characteristics. This digital copy can be analyzed automatically without physical contact, enabling high-speed automated quality control while preserving measurement accuracy through precise digital analysis of the optical signature.
3Reliability
If in-line quality validation is performed, then non-compliant reflectors can be rejected promptly, but the validation process requires significant implementation costs
Solution Approach 1:
The patent segments the quality validation process into distinct functional modules: a light source module for illumination, an imaging device module for light capture, and an image processing module for analysis. This segmentation allows each module to be optimized independently and facilitates integration into existing production lines. The modular architecture reduces overall system complexity while maintaining reliable quality validation through coordinated operation of specialized components.
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
Enables quick, accurate, and automatic validation of reflector quality, reducing production costs and errors by objectively determining compliance with predetermined parameters.
Implementation Method 1
at least one first light source, which is designed to emit a first predetermined light beam to irradiate the reflecting surface of said reflector body
Implementation Method 2
emit a first predetermined light beam to irradiate the reflecting surface of said reflector body
Implementation Method 3
an image capturing apparatus, which is arranged so as to capture one or more first images containing the irradiated reflecting surface of said reflector body
Data Source
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AI summary
A control system to control the quality of at least one reflector body (P1) of a lamp of a motor vehicle, comprising a light source (10), which is designed to emit a first light beam (F1) to irradiate the reflecting surface (PA1) of the reflector body (PI); an image capturing apparatus (11), which is arranged so as to capture a series of images (IMG1 (i)) containing the irradiated reflecting surface of the reflector body (PI); a processing device (12), which is configured so as to process the images (IMG1(i)), in order to determine the actual reflectance (R1) of the reflector body (PI), and so as to determine a quality condition of the reflector body (P1) to be validated based on the actual reflectance (R1).