Modular Automated Inspection With Preconfigured Imaging Parameters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automated inspection technologies are inefficient and costly due to complexity, requiring skilled personnel and dedicated hardware, making them unsuitable for low-cost or low-margin parts, and often result in imprecise results due to manual configuration and sub-optimal image capture settings.
Innovation Solution
A universal inspection system with a modular design incorporating illumination devices, sensors, and articulating arms, allowing for intuitive configuration using pre-computed inspection parameters, enabling efficient inspection of various parts with minimal downtime and training, and capable of adapting to different products without significant reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used, then inspection can be conducted without specialized equipment, but inspection accuracy and consistency deteriorate due to human error and fatigue
Solution Approach 1:
The system performs self-configuration by automatically determining inspection parameters, illumination settings, and capture conditions without requiring skilled personnel to manually configure the system. The processing device autonomously analyzes part geometry and optimizes inspection settings based on pre-computed parameters stored in the database.
Solution Approach 2:
Inspection parameters, illumination settings, and capture conditions are pre-computed and stored in a database before actual inspection occurs. When a part is inspected, the system retrieves and applies these pre-optimized parameters, eliminating the need for real-time manual configuration and ensuring consistent high-quality results.
2Measurement precision
If dedicated inspection hardware is used, then inspection precision is improved, but system cost and complexity increase making it unsuitable for low-margin parts
Solution Approach 1:
The inspection system is designed with universal components that can inspect multiple types of parts across different industries. The modular architecture with interchangeable illumination devices, sensors, and articulating arms allows a single system to perform various inspection tasks, eliminating the need for dedicated expensive hardware for each specific inspection application.
Solution Approach 2:
The system achieves different inspection capabilities by changing software parameters and configuration settings rather than requiring different physical hardware. By adjusting illumination parameters, sensor settings, and inspection algorithms, the same physical system can be optimized for inspecting diverse parts with varying requirements, significantly reducing overall system cost.
3Measurement precision
If complex automated inspection systems are used, then inspection precision is improved, but ease of operation deteriorates requiring skilled personnel for configuration
Solution Approach 1:
The system performs self-configuration by automatically determining inspection parameters, illumination settings, and capture conditions without requiring skilled personnel to manually configure the system. The processing device autonomously analyzes part geometry and optimizes inspection settings based on pre-computed parameters stored in the database.
Solution Approach 2:
A database serves as an intermediary between the complex inspection hardware and the user, storing pre-computed inspection parameters and optimization algorithms. This intermediary layer translates complex technical requirements into automated configuration processes, shielding users from the underlying complexity while maintaining high inspection precision.
4Productivity
If manual configuration of inspection parameters is used, then system simplicity is maintained, but inspection efficiency and image capture quality deteriorate
Solution Approach 1:
Inspection parameters, illumination settings, and capture conditions are pre-computed and stored in a database before actual inspection occurs. When a part is inspected, the system retrieves and applies these pre-optimized parameters, eliminating the need for real-time manual configuration and ensuring consistent high-quality results.
Solution Approach 2:
The system automatically adjusts multiple parameters including illumination intensity, sensor exposure settings, capture resolution, and articulating arm positioning based on the specific part being inspected. This automated parameter optimization significantly improves inspection efficiency and image quality without requiring manual intervention.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Systems, methods, and related technologies for automated inspection are described. In certain aspects, one or more images of a reference part can be captured and the one or more images of the reference part can be processed to generate an inspection model of the reference part. One or more regions of the inspection model can be associated with one or more analysis parameters. An inspection plan can be generated based on the inspection model and the one or more analysis parameters. Based on the inspection plan, one or more images of a part to be inspected can be captured and the one or more images of the part can be processed in relation to the analysis parameters to compute one or more determinations with respect to the part. One or more outputs can be providing based on the one or more determinations.