Mirror-Based Multi-Surface Product Inspection System
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Solution Overview
Problem
Conventional product inspection methods are either time-consuming and inefficient when using a single camera to capture multiple surfaces or costly and space-intensive when using multiple cameras, and they struggle to accurately associate images of different product surfaces due to independent image capture.
Innovation Solution
A product inspection system employing a single camera and a circular arrangement of mirrors to capture multiple sides of a product simultaneously, with a calibration member to determine the relative mirror positions, allowing for the splicing of sub-images into a complete inspection image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single camera is used to capture multiple surfaces of a product, then the cost and device complexity are reduced, but the inspection time increases and shooting efficiency decreases
Solution Approach 1:
The patent introduces mirrors to reflect light from multiple product surfaces into a single camera, effectively adding spatial dimensions to the image capture process. This allows the camera to capture images of multiple surfaces simultaneously by redirecting light paths through mirror reflections, thereby maintaining high productivity while using a simple single-camera system.
Solution Approach 2:
Mirrors are introduced as intermediary elements between the product surfaces and the camera. These mirrors capture and redirect light from different product surfaces to the single camera sensor, enabling the camera to indirectly capture multiple surfaces at once without requiring multiple cameras or mechanical movement.
2Productivity
If multiple cameras are used to capture images of multiple surfaces simultaneously, then the shooting efficiency is improved, but the cost and operation space increase
Solution Approach 1:
The patent merges the functions of multiple cameras into a single camera by using mirrors to combine light paths from multiple product surfaces into one camera sensor. This consolidation maintains the simultaneous capture capability of multiple surfaces while reducing the number of cameras needed, thereby lowering cost and device complexity.
Solution Approach 2:
The single camera system is made multi-functional through the use of mirrors, allowing it to perform the function of multiple cameras by capturing images of different product surfaces simultaneously. The mirror arrangement enables the single camera to serve multiple viewing angles and surfaces that would otherwise require separate cameras.
3Device complexity
If images of multiple surfaces are captured independently, then the device complexity is reduced, but the ability to determine position relationships and associate images with product features is lost
Solution Approach 1:
A calibration member with known geometric relationships is introduced as an intermediary to establish the spatial relationships between mirror positions. By capturing images of this calibration member with known features, the system can calculate and store the relative positions and orientations of mirrors, enabling accurate position relationship determination for subsequent product inspections.
Solution Approach 2:
The system performs a preliminary calibration step by imaging a calibration member with known geometric features before actual product inspection. This preliminary action establishes the spatial relationships between mirrors and creates a reference coordinate system, which is then used to accurately associate product feature images with their corresponding positions on the actual product.
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 approach enables efficient, cost-effective, and accurate inspection of multiple product surfaces without the need for multiple cameras, allowing for precise determination of feature positions and patterns across the product's circumference.
Implementation Method 1
the camera receives light from the calibration member reflected by the mirrors to generate a calibration image of the calibration member
Data Source
AI summary
A product inspection system includes an image acquisition system having a camera generating an inspection image of a product arranged between a plurality of mirrors. The inspection image has a plurality of sub images of different sides of the product. The inspection system has a calibration member with a plurality of correction patterns on different sides; the camera receives light from the calibration member reflected by the mirrors to generate a calibration image of the calibration member. A computer of the product inspection system receives the inspection image and the calibration image and determines a relative mirror position relationship between the mirrors. The computer forms a single spliced image of the product.