Dual-Surface Leather Inspection Using Direct and Indirect Lighting
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Solution Overview
Problem
Leather hides often contain inconsistencies such as holes, scars, scratches, and dirt on both surfaces, which can affect the appearance and quality of leather products, and existing methods lack efficient automated systems for detecting and indicating these defects on both surfaces simultaneously.
Innovation Solution
An apparatus comprising a frame with movable camera assemblies for both surfaces of the leather hide, coupled with a computing device to detect and digitally store inconsistencies, and a marking system to physically indicate defect locations on the upper surface, utilizing direct and indirect lighting for comprehensive inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to detect inconsistencies on leather hides, then operators can identify defects, but the process is time-consuming and labor-intensive with reduced productivity
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system comprising cameras, light sources, and image processing equipment. The system captures images of leather hides and uses computational algorithms to automatically detect and classify inconsistencies, eliminating the need for manual visual inspection while maintaining high detection accuracy and significantly improving inspection throughput
Solution Approach 2:
The inspection system performs self-assessment by automatically analyzing leather hide images without human intervention. The computing device independently processes images, identifies defects, classifies them by type and severity, and generates inspection reports, enabling the system to serve its own inspection function without requiring external human operators
2Measurement precision
If inspection systems only check one surface of the leather hide, then the system complexity is reduced, but defects on the other surface remain undetected
Solution Approach 1:
The inspection system is divided into separate inspection modules for the upper surface and lower surface of the leather hide. Each module includes dedicated cameras and light sources positioned to capture images of specific surfaces. This segmentation allows the system to comprehensively inspect both surfaces while maintaining manageable complexity through modular architecture
Solution Approach 2:
The system extends inspection from a single surface to both surfaces of the leather hide by adding inspection capabilities in the vertical dimension. Cameras and light sources are positioned above and below the hide to capture images of both upper and lower surfaces, transforming the inspection from two-dimensional (one surface) to three-dimensional (both surfaces) coverage
3Measurement precision
If single lighting condition inspection is used, then the lighting setup is simpler, but inconsistencies with different reflectivity characteristics cannot be adequately detected
Solution Approach 1:
Different lighting conditions are applied to different inspection scenarios: diffuse lighting is used for general surface inspection, while directional lighting is used specifically for detecting scratches and texture variations. The system selectively activates appropriate light sources based on the inspection requirements, providing locally optimized lighting quality for different defect types without requiring all lighting systems to operate simultaneously
Solution Approach 2:
The system changes lighting parameters such as intensity, direction, and color temperature to optimize defect detection. By varying these parameters, the system enhances the visibility of different types of inconsistencies including scratches, dents, and color variations, improving detection precision while managing lighting system complexity through parameter adjustment rather than hardware multiplication
Data Source
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AI summary
The present invention relates to a leather inspection apparatus for detecting inconsistencies on a surface of a leather hide, comprising: a frame capable of supporting the leather hide; a camera assembly movably coupled to the frame and capable of movement along a surface of the leather hide, wherein the camera assembly includes a first camera and a second camera; a computing device operatively coupled to the camera assembly; wherein the camera assembly detects the locations of inconsistencies in the surface of the leather hide, wherein the computing device digitally stores the locations of the inconsistencies of the surface of the leather hide, and wherein the first camera detects inconsistencies based on direct lighting and the second camera detects inconsistencies based on indirect lighting.