Optical Lens Defect Detection via Image Recombination
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Solution Overview
Problem
Current cosmetic control of optical lenses is manual and lacks reliability, making it difficult to accurately detect defects during the manufacturing process and store control data effectively.
Innovation Solution
A method involving image reception, sampling, recombination, and defect detection using specific patterns with bright and dark areas to create a recombined image for enhanced defect visibility, allowing for automated and reliable cosmetic control of optical lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cosmetic control is used, then operational simplicity is maintained, but detection reliability and precision deteriorate
Solution Approach 1:
The patent replaces manual cosmetic control with an automated optical inspection system using cameras and image processing algorithms. The system captures images of the lens surface under controlled lighting conditions and automatically analyzes them to detect defects, eliminating human operators while improving detection reliability and consistency.
Solution Approach 2:
The patent creates digital copies (images) of the lens surface and analyzes these copies rather than directly examining the physical lens. Multiple images are captured from different angles and lighting conditions, then processed to create a comprehensive defect detection system that maintains high reliability without requiring complex manual inspection procedures.
2Productivity
If automated control is implemented, then productivity increases, but measurement precision and defect detection accuracy deteriorate
Solution Approach 1:
The patent divides the lens surface into multiple zones and captures images from different angles and lighting conditions for each zone. The inspection process is segmented into multiple imaging steps with specific lighting patterns, allowing the system to maintain high precision by analyzing each segment separately while achieving high productivity through automated processing of all segments.
Solution Approach 2:
The patent uses periodic lighting patterns and sequential imaging to capture the lens surface under varying conditions. The system systematically cycles through different lighting configurations and capture angles, processing each image through automated algorithms that maintain high measurement precision while the rapid sequential processing ensures high productivity.
3Measurement precision
If multiple images are captured and processed, then defect detection precision improves, but processing time and complexity increase
Solution Approach 1:
The patent performs preliminary image capture and processing steps that prepare the data for final defect analysis. Multiple images are captured and pre-processed to create optimized datasets, and the system uses these pre-processed images for rapid defect detection, reducing the time required for final analysis while maintaining high precision through the comprehensive preliminary imaging.
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 method enables reliable detection and visualization of defects, particularly diffusing defects, with increased visibility and accuracy, facilitating improved sorting and control of optical lenses during manufacturing.
Implementation Method 1
a view of the zone of interest in front of a plurality of specific patterns
Implementation Method 2
optical lens positioning step, during which the optical lens is positioned on the support
Data Source
AI summary
Method for detecting a defect in a zone of interest of an optical lens, the method including: an image reception step, during which a plurality of images is received, each image includes a view of the zone of interest in front of a plurality of specific patterns, each specific pattern including a bright area and a dark area, and at least one image received is saturated in light intensity; a sampling step, during which each image of the plurality of images are sampled based on a common sampling pattern; a recombination step, during which a recombined image of the zone of interest is determined based on the common sampling pattern; and a defect detection step, during which a defect is detected in the zone of interest of the optical lens based on an analysis of the recombined image.