Laser-Integrated Imaging Focus Calibration for Conveyor Lines
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Solution Overview
Problem
Traditional imaging systems fail to adapt camera settings to the individual characteristics of objects, leading to varying image quality, especially in conveyance lines where the distance between the imaging system and the imaged object is object-dependent.
Innovation Solution
Incorporating a height detection sensor and a programmable logic controller (PLC) to receive sensor data, modify the focus level of the imaging device based on object attributes, and initiate a validation image at the calibrated focus level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional imaging systems use fixed camera settings, then the system structure remains simple, but image quality varies due to object distance differences
Solution Approach 1:
The system performs preliminary height detection using a laser sensor before imaging, and pre-calibrates focus levels for different height ranges. This preliminary measurement and preparation enable the imaging device to adjust settings in advance, ensuring consistent image quality across objects at different distances without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The system implements a feedback loop where the laser height sensor continuously measures object distance, the PLC processes this data to determine optimal focus levels, and the imaging device adjusts its settings accordingly. This closed-loop feedback mechanism maintains image quality consistency while using standardized industrial components, balancing performance with system complexity.
2Manufacturing precision
If camera settings are manually calibrated for each object, then image quality improves, but the operation time and complexity increase
Solution Approach 1:
The system establishes multiple pre-calibrated focus levels corresponding to different object height ranges during setup. During operation, the laser sensor measures object height and the PLC automatically selects the appropriate pre-calibrated focus level based on measured parameters. This eliminates manual recalibration for each object while maintaining optimized image quality, significantly reducing operation time compared to individual calibration.
Solution Approach 2:
The system dynamically adjusts camera focus settings based on real-time height measurements from the laser sensor. Rather than static fixed settings or time-consuming manual calibration, the imaging parameters automatically adapt to each object's characteristics, achieving both high image quality and efficient throughput in conveyor line applications.
3Adaptability or versatility
If the imaging system adapts to each object, then image quality consistency improves, but the device complexity increases
Solution Approach 1:
The system uses a laser height sensor and PLC configuration that can handle multiple object types and height ranges with a single setup. The pre-calibrated focus levels serve as a universal solution for various objects on the conveyor line, eliminating the need for object-specific hardware modifications while maintaining adaptability. This multi-functional approach achieves object-to-object adaptation without proportionally increasing system complexity.
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
Enhances image quality consistency by adaptively calibrating the focus level of imaging devices to individual object characteristics, improving the continuous verification of items on conveyance lines.
Implementation Method 1
a laser sensor mounted to the imaging device
Implementation Method 2
laser sensor... that receive sensor data reflective of the attributes of an object
Data Source
AI summary
Various embodiments of the present disclosure provide an imaging system that includes an imaging device, a height detection sensor, and a programmable logic controller configured to receive sensor data from the height detection sensor, modify a focus level of the imaging device to one of a plurality of calibrated focus levels based on the sensor data; and initiate a validation image at the focus level.