LED Matrix Lighting Device with Oblique Refraction for Uniform Illumination
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Solution Overview
Problem
Existing LED lighting devices used in continuous manufacturing processes, such as paper and cardboard machines, often fail to provide uniform illumination due to space constraints, resulting in non-uniform brightness across the illuminated surface, which affects the quality of images captured by cameras monitoring the moving web.
Innovation Solution
An LED matrix lighting device with a collimating lens and a light refracting element that refracts light at different angles for each LED, allowing individual control of current to each LED to ensure even luminous intensity across the illumination pattern, combined with a data processing device for adjusting current based on detected intensity deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED lighting device is mounted perpendicular to the paper web, then uniform illumination pattern can be provided, but space constraints prevent mounting above or under the moving web
Solution Approach 1:
The patent changes the mounting dimension from perpendicular (above/below) to oblique (side mounting at 30-60 degrees angle), allowing the lighting device to be positioned in available side space while still illuminating the web surface effectively
Solution Approach 2:
The patent applies individual current control to each LED or groups of LEDs to compensate for non-uniform illumination caused by oblique mounting, creating uniform brightness across the illuminated area through localized adjustment of lighting parameters
2Area of stationary object
If LED lighting device is mounted at an angle of 30 to 60 degrees to the paper web, then space constraints are satisfied, but illumination pattern becomes non-uniform with different brightness in different parts
Solution Approach 1:
The patent controls current individually or in groups for each LED based on its position in the matrix, compensating for the non-uniform illumination pattern caused by oblique mounting by adjusting local brightness to achieve overall uniformity
Solution Approach 2:
The system uses captured images to detect intensity deviations in the illumination pattern and uses this feedback to adjust current provided to individual LEDs or groups, automatically correcting non-uniformity in real-time
3Speed
If very short shutter speed times are used to capture images of the moving web, then motion blur is reduced, but image quality becomes significantly dependent on illumination
Solution Approach 1:
The patent changes the illumination parameter from fixed intensity to dynamically adjustable intensity for each LED, allowing optimization of light output to match the requirements of short shutter speed photography and ensuring sufficient illumination for high-speed capture
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 ensures uniform illumination intensity across the entire surface, improving the quality of images captured by cameras and enhancing the detection of deviations in the manufacturing process.
Implementation Method 1
a collimating lens in front of each LED for collimating light of the LED
Implementation Method 2
a light refracting element in front of collimating lenses arranged to refract light of at least a first part of the LEDs with a different refraction angle than at least a second part of the LEDs
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to an LED matrix lighting device (20) for illuminating a lighting pattern with even intensity. The LED matrix lighting device comprises a plurality of LEDs (22), a collimating lens (23) in front of each LED (22) for collimating light of the LED (22), and a light refracting element (24) in front of collimating lenses (23) arranged to refract light of at least a first part of the LEDs (22) with a different refraction angle than at least a second part of the LEDs (22). The invention further relates to a machine vision system, a method, and a computer program product.