Matrix Chip Camera Active Area Synchronization for Web Offset
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Solution Overview
Problem
Existing inspection systems for material railways face challenges in compensating for material track offsets, particularly when using software compensation, which can be complex and unsatisfactory, especially at higher rail speeds and with different lighting types.
Innovation Solution
The solution involves a procedure and device that dynamically adapt the active sub-areas of a matrix chip camera to synchronize image sequences directly, independent of material railway properties, thereby eliminating the need for complex software compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If software compensation is used to correct material web offset, then image alignment can be achieved, but system complexity and computing power requirements increase significantly
Solution Approach 1:
The patent replaces the software-based image stabilization algorithm with a hardware-based solution. The camera device uses a movable lens assembly that can physically adjust the optical path to compensate for material web offset in real-time, eliminating the need for complex software processing while achieving the same alignment precision
Solution Approach 2:
The patent introduces an intermediary component - the movable lens assembly with adjustable optical path - that acts as a mediator between the camera sensor and the moving material web. This intermediary mechanically compensates for the offset before the image is captured, simplifying the overall system compared to post-capture software correction
2Reliability
If software image stabilization algorithm is used, then image sequences can be aligned, but the system becomes complex and sometimes impossible to implement
Solution Approach 1:
The patent replaces the software image stabilization algorithm with a hardware-based solution. The camera device uses a movable lens assembly that can physically adjust the optical path to compensate for material web offset in real-time, eliminating the need for complex software processing while achieving the same alignment precision
Solution Approach 2:
The patent performs the compensation action before the image is captured. The movable lens assembly proactively adjusts the optical path based on predicted or measured offset, preventing misalignment from occurring in the first place rather than correcting it through complex post-processing algorithms
3Area of stationary object
If the entire matrix chip area is used for imaging, then complete material web coverage is achieved, but image recording frequency decreases due to readout time
Solution Approach 1:
The patent divides the matrix chip into multiple independently controllable regions. Instead of reading out the entire chip simultaneously, the system can selectively activate and read out only the necessary segments, reducing readout time and increasing frame rate while maintaining adequate coverage of the moving material web
Solution Approach 2:
The patent introduces dynamic control of the matrix chip activation. The system can dynamically adjust which portions of the matrix chip are active based on the current position and speed of the material web, optimizing the balance between coverage area and recording frequency in real-time
Data Source
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AI summary
The invention relates to a device and a method for compensating for web misalignment in inspection systems for webs moving along a web length and/or width. The method comprises the following steps: first, taking a picture of a first section of a web at a first time point with a camera comprising a matrix chip, and second, taking a picture of a second section of the web at a second time point with the same camera. For the first picture, a first active area of the matrix chip is used, and for the second picture, a second active area of the matrix chip is used, wherein the first and second active areas are not identical.