Lighting Device for Defect Localization on Moving Specimens
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Solution Overview
Problem
Automated fault detection and quality control in manufacturing processes, particularly for glass products, often struggle to reliably distinguish between defects and contaminants, leading to inefficient manual checks due to the complexity of applying and removing color markings, which are costly and time-consuming.
Innovation Solution
A lighting device with adjustable illumination patterns and colors is used to directly mark the location of defects on the surface of test objects, allowing for rapid and precise manual inspection by illuminating a small, definable area around the defect, and optionally darkening surrounding areas, with the ability to adapt marking based on defect type and size, and move with continuously moving specimens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If color markings are applied to mark defect locations, then defect localization is improved, but the process becomes costly and time-consuming due to complex application and removal procedures
Solution Approach 1:
The patent replaces the mechanical system of applying and removing color markings with an optical system that uses a light source to directly illuminate defect locations. The lighting device projects light onto the test object surface at the identified defect positions, eliminating the need for physical marking materials and their subsequent removal, thereby reducing both time and cost while maintaining precise defect localization.
2Productivity
If automated inspection devices are used, then inspection speed is improved, but reliability decreases due to inability to reliably distinguish between defects and contaminants
Solution Approach 1:
The patent merges automated defect detection with manual inspection verification. The system first uses automated inspection to identify potential defect locations and mark them with light, then guides manual inspectors to verify whether these marked locations represent true defects or removable contaminants. This combination maintains high inspection speed while improving reliability through human judgment on ambiguous cases.
Solution Approach 2:
The lighting device acts as an intermediary between automated detection and manual verification. It provides visual guidance to manual inspectors by illuminating specific locations, enabling them to quickly verify suspected defects without having to manually inspect entire surfaces, thus maintaining productivity while enhancing reliability through targeted human assessment.
3Reliability
If manual inspection is performed on large surfaces, then inspection thoroughness is improved, but time consumption increases significantly
Solution Approach 1:
The system performs preliminary automated scanning to identify and mark potential defect locations before manual inspection begins. This preliminary action reduces the manual inspection task from examining entire large surfaces to verifying only the marked locations, thereby maintaining thoroughness while dramatically reducing the time required for manual verification.
Solution Approach 2:
The patent segments the large surface inspection task into multiple discrete marked locations. Instead of requiring manual inspection of the entire large surface area, the system divides the work by illuminating only the specific coordinates where defects were detected, allowing inspectors to focus on segmented target areas and complete thorough inspection much faster.
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
This solution enables quick and reliable localization of defects, reducing the need for multiple comparisons and minimizing unnecessary effort in manual checks, thereby streamlining the inspection process and reducing costs.
Implementation Method 1
a lighting device (12) with at least one light source (8), by means of which an illuminated display marking the position of the defect (2) on the surface (20) or on at least one adjacent side edge (7) of the test piece (3) can be generated
Data Source
Figure 1~2
Figure 3~6
AI summary
In a method for indicating automatically identified flaws on or in a test specimen (3), wherein a location of a defect (2) on or in a test specimen identified by an inspection unit is subsequently indicated, a lighting unit (12), for example color LEDs, is used to generate an illuminated indicator marking the location of the defect (2) on the surface or on at least one adjoining lateral edge (7) of the test specimen (3). After the automatic identification of the flaw, it is checked on the basis of quantifiable properties of the defect (2) whether the defect (2) meets a predefinable quality criterion, and an illuminated indicator marking the location of the defect (2) at or on the test specimen (3) is generated only if the quality criterion is not met. The coloring of the marking illuminated indicator is predefined depending on quantifiable properties of the defect (2).