Lens Control System for Consistent Imaging Settings
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Solution Overview
Problem
Conventional image processing apparatuses in factory automation lines face difficulties in numerically managing and replicating settings for lens units, particularly in adjusting zoom, focus, and iris functions, leading to inconsistencies across multiple lines and challenges in identifying incorrect settings during maintenance.
Innovation Solution
The image processing apparatus includes a controller and imaging device with a correction table storage unit that adjusts and corrects setting values for lens and illumination units, allowing for remote numerical management and standardization across multiple devices, using a single setting value for multiple imaging devices and enabling easy recreation of settings during device replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of lens unit is used, then ease of operation is maintained, but manufacturing precision and reliability of settings are degraded
Solution Approach 1:
The patent replaces manual mechanical adjustment of the lens unit with an automated control system. The controller receives setting values and automatically adjusts the lens unit's operation conditions (zoom, focus, iris) through control signals, eliminating the need for manual rotation of rings or manual voltage/current adjustment while viewing a monitor.
Solution Approach 2:
The patent changes the control parameters from manual physical adjustments to numerical setting values that can be transmitted and stored. The controller manages the lens unit through numerical parameters (setting values) that define specific operation conditions, enabling precise and reproducible settings across multiple devices and locations.
2Ease of operation
If remote control of imaging devices is implemented, then ease of operation is improved, but the ability to numerically manage settings is degraded
Solution Approach 1:
The patent implements a feedback mechanism where the controller receives setting values, transmits them to the imaging device, and can retrieve actual operation condition information. This closed-loop system ensures that numerical setting values are properly transmitted, stored, and can be verified, preventing loss of numerical management capability while maintaining remote control functionality.
Solution Approach 2:
The patent uses setting values as digital copies of the desired operation conditions. These numerical settings can be stored in the controller or external storage, transmitted to multiple imaging devices, and used to recreate identical settings across different devices and locations, enabling precise numerical management alongside remote control.
3Device complexity
If manual adjustment methods are used, then device complexity is reduced, but loss of time for setting and maintenance increases
Solution Approach 1:
The patent implements preliminary action by pre-defining setting values for various operation conditions. These setting values can be prepared in advance, stored in the controller or external storage devices, and quickly transmitted to imaging devices when needed, eliminating the time-consuming manual adjustment process while maintaining reasonable system complexity.
4Manufacturing precision
If numerical management of lens settings is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements universality by designing a control system that can manage multiple imaging devices with the same controller. The controller can transmit and store setting values for different devices, and the same numerical management approach can be applied across zoom, focus, and iris functions, as well as illumination units, reducing overall system complexity through standardized control methodology.
Data Source
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AI summary
An external I/F gives numerical information on an imaging device, input from PC or PLC, to a memory. The memory outputs the numerical information to CPU as well as retaining the numerical information. CPU transmits the numerical information through a camera to an operation control unit. The operation control unit performs correction using a correction value from a correction table. In order to correct a variation individually possessed by a lens unit or an illumination unit, the correction table is previously produced for each lens unit or illumination unit based on the numerical information from the camera. The post-correction control signals are output to a lens unit 62 and an illumination unit.