Mirror-Based Visual Inspection for Defect vs Luminance Distinction
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Solution Overview
Problem
Existing visual inspection technologies erroneously detect luminance unevenness as defects, leading to re-inspection and reduced productivity, and using articulated robots increases inspection man-hours and facility complexity.
Innovation Solution
A visual inspection apparatus with a rotational portion, mirror, imaging portion, and adjustment portion to rotate and adjust the imaging angle, allowing accurate distinction of defects and luminance unevenness without increasing man-hours or facility complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a visual inspection apparatus images mirror images using a reflection mechanism, then multiple surface views can be inspected without complicated imaging mechanisms, but luminance unevenness is erroneously detected as defects
Solution Approach 1:
The imaging portion dynamically changes the imaging angle relative to the inspection target by rotating the imaging portion around the central axis of the inspection target. This dynamic angle adjustment allows the system to capture images at multiple angles and distinguish between luminance unevenness (which appears consistent across angles) and actual defects (which show variations), thereby resolving the contradiction between inspection efficiency and defect detection accuracy.
2Measurement precision
If an articulated robot swings the inspection target to change relative posture, then accuracy of distinguishing defect and luminance unevenness is improved, but inspection facility becomes complicated and man-hours increase
Solution Approach 1:
Instead of moving the inspection target (as done with articulated robots), the invention inverts the approach by keeping the inspection target stationary and rotating the imaging portion around the target's central axis. This inversion simplifies the facility structure while maintaining the ability to capture images at multiple angles for accurate defect distinction, thereby resolving the contradiction between detection accuracy and facility complexity.
3Illumination intensity
If the imaging portion captures images in bright field regions, then sufficient illumination is achieved, but luminance unevenness causes false defect detection
Solution Approach 1:
The system dynamically adjusts the imaging angle by rotating the imaging portion around the inspection target's central axis. By capturing images at multiple angles, the system can identify luminance unevenness patterns that remain consistent across angles versus actual defects that show variations. This dynamic angular adjustment allows sufficient illumination to be maintained while improving defect detection accuracy by distinguishing true defects from luminance variations.
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
Improves productivity by enhancing defect and luminance unevenness detection accuracy while reducing inspection time and facility complexity.
Implementation Method 1
a mirror portion (3) provided so as to reflect the inspection target
Data Source
AI summary
A visual inspection apparatus of the present invention includes a rotational portion configured to rotate in a state that an inspection target is placed on the rotational portion, a mirror portion provided so as to reflect the inspection target in the state that the inspection target is placed on the rotational portion, an imaging portion configured to image the inspection target reflected in the mirror portion, an adjustment portion configured to change an imaging angle of the imaging portion relative to the inspection target reflected in the mirror portion, and an inspection portion configured to inspect a surface of the inspection target based on image data captured by the imaging portion.