Configurable Machine Vision Lighting With Segmented PCB Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional light sources are inadequate for capturing high-quality images of industrial products with diverse surface materials and features, and they struggle to provide consistent lighting in different environments, leading to reduced accuracy in image detection.
Innovation Solution
A configurable light source system with individually addressable light channels, controlled by a controller, and a sealed housing design that includes metal-based PCBs and flexible circuits for heat management and contamination prevention, along with diffusers for optimal lighting and image capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional light sources are used for imaging industrial products, then the device complexity is low, but the measurement precision and reliability of image detection are reduced
Solution Approach 1:
The light source is divided into multiple independently controllable light channels, each with specific incidence angles and patterns. This segmentation allows precise control of lighting for different surface features, improving measurement precision while managing complexity through modular design
Solution Approach 2:
The configurable light source system is designed to handle diverse surface materials and features (reflective, transparent, black surfaces, scratches, dirt) with a single multi-functional device, improving measurement precision across various inspection scenarios without requiring multiple specialized light sources
2Adaptability or versatility
If conventional light sources are used, then the device complexity is low, but the adaptability to different environments and surface materials is insufficient
Solution Approach 1:
The light source system allows dynamic configuration of multiple light channels with adjustable incidence angles and patterns, enabling adaptation to different surface materials and environmental conditions. This dynamic controllability enhances versatility while the modular architecture manages configuration complexity
Solution Approach 2:
The system changes lighting parameters (incidence angle, light pattern, channel activation) to optimize performance for different surface materials and features. This parameter adjustability provides high adaptability across diverse inspection scenarios
3Measurement precision
If manual manipulation of distance and geometry is performed to capture high-quality images, then the measurement precision is improved, but the productivity and ease of operation are reduced
Solution Approach 1:
The light source is pre-configured with multiple channels at specific incidence angles and patterns optimized for different surface features. This preliminary configuration eliminates the need for manual distance and geometry manipulation during inspection, maintaining high image quality while improving productivity
Solution Approach 2:
The configurable light source system automatically provides appropriate lighting conditions for different inspection scenarios through its multi-channel design, eliminating the need for manual operator intervention to adjust distance and geometry, thus improving both productivity and ease of operation
4Measurement precision
If manual manipulation is performed to achieve high-quality images, then the measurement precision is improved, but the ease of operation is reduced
Solution Approach 1:
The light source system automatically provides optimized lighting conditions through its pre-configured multi-channel design, eliminating the need for manual manipulation of distance and geometry. This self-service capability maintains high image quality while significantly improving ease of operation
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 system provides flexible and high-quality lighting for diverse industrial products, enhancing image capture accuracy and reliability by addressing heat management and environmental contamination issues.
Implementation Method 1
The PCB substrate is formed of a ductile material, the PCB substrate comprising segments corresponding to the facets of the inner surface of the body
Implementation Method 2
A configurable light source system with individually addressable light channels, controlled by a controller, and a sealed housing design that includes metal-based PCBs and flexible circuits for heat management and contamination prevention, along with diffusers for optimal lighting and image capture
Data Source
AI summary
A feature inspection lighting system comprises a body including an inner surface, the inner surface having facets defined therein. A PCB substrate formed of a ductile material is mounted to the inner surface of the body. The PCB substrate comprises segments corresponding to the facets of the inner surface of the body. Light emitters are mounted to the PCB substrate. The thermal interface between the segments of the PCB substrate and the facets of the body facilitates heat transfer. A flexible PC electrically connects the PCB substrate to a cable for supplying power to the lighting system. One or more diffusers are provided to achieve the desired illumination of a target object and to seal the interior of the assembly from contaminants.