Semi-Circular LED Illuminator for Cylindrical Surface Inspection
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Solution Overview
Problem
Existing illumination devices for curved surfaces, such as cylindrical parts, require complex structures with multiple lighting sources and optical elements, limiting flexibility in camera positioning and increasing costs, while also necessitating rigid camera locations.
Innovation Solution
A compact, low-cost illuminator with a semi-circular array of LEDs or electro luminescent strips that provides uniform diffused light over 180 degrees, eliminating the need for dual light sources, beam splitters, and reflecting domes, allowing flexible camera placement and maintaining a brightfield effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If complex structures with multiple lighting sources and optical elements are used, then uniform illumination of cylindrical surfaces is achieved, but device complexity and cost increase
Solution Approach 1:
The illumination device is segmented into three distinct light sources positioned at specific locations (top, left, right) around the cylindrical surface, each illuminating a specific sector. This segmentation allows uniform illumination across the entire surface while using simple, individual light sources rather than a complex single-source system with multiple optical elements.
Solution Approach 2:
The patent combines multiple simple light sources (LEDs or other illumination devices) positioned at different locations to achieve the illumination effect that would otherwise require complex optical elements like beam splitters and reflecting domes. By merging the illumination functions of three separate sources, the system achieves uniform coverage without complex individual components.
2Illumination intensity
If rigid camera locations are dictated by complex illumination structures, then uniform illumination is maintained, but adaptability and ease of operation decrease
Solution Approach 1:
The illumination system is designed with dynamic adaptability where the three light sources can be independently positioned and adjusted. This allows the illumination geometry to adapt to different camera positions and different cylindrical surfaces, eliminating the rigid camera location constraints imposed by fixed complex optical structures while maintaining uniform illumination.
Solution Approach 2:
The illumination device is designed to be universally applicable to various cylindrical surfaces and camera positions. The three light sources can be configured for different geometries and angles, making the system multi-functional and adaptable rather than requiring specific rigid positioning, thus serving multiple inspection scenarios with a single flexible system.
3Illumination intensity
If multiple optical elements like beam splitters and reflecting domes are used, then illumination uniformity is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent replaces expensive, complex optical elements like beam splitters and reflecting domes with inexpensive LED light sources and simple positioning structures. The three light sources are standard, readily available components that are much cheaper to manufacture and install than precision optical elements, while achieving the same uniform illumination effect through geometric positioning rather than optical manipulation.
4Illumination intensity
If complex illumination structures are used, then uniform illumination is achieved, but the footprint and overall dimensions of the device increase
Solution Approach 1:
Instead of using complex optical elements that require significant spatial separation and large footprints, the patent positions three light sources in three-dimensional space around the cylindrical surface at optimized angles and distances. By utilizing spatial dimensionality and angular positioning rather than extended optical paths, the system achieves uniform illumination with a compact footprint suitable for inline inspection systems.
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
The solution achieves even illumination of cylindrical surfaces, providing high contrast for symbology and eliminating specular reflections, while allowing for flexible camera positioning and reducing overall dimensions, thus simplifying the mounting and operation of camera systems.
Implementation Method 1
A compact, low-cost illuminator with a semi-circular array of LEDs or electro luminescent strips that provides uniform diffused light
Implementation Method 2
light rays reflect off that surface and back to a camera/lens combination and result in a uniform 'even' image
Data Source
AI summary
A plurality of LED's, or electro luminescent strips, are disposed to project illumination to and thru, or towards, a diffuser; resulting in at least a portion of generated diffuse illumination being directed towards and upon the cylindrical surface of an article or part when disposed at an article illumination location. The article illumination location is established so that a centerline through the article is co-linear with a center line of the diffuse illumination projecting from, or reflected from, the diffusers. A housing may be provided for the LED's, electro luminescent strips and diffusers; or they may be otherwise arranged to coact to provide diffuse illumination directed towards the cylindrical surface of the part or other article. illumination reflected off of the article's cylindrical surface, and/or any markings, such as symbology, carried thereby is directed to a lens/camera arrangement to provide an image of same for transmission to a computer, controller, smart camera or other image utilization system.