Modular Optical Inspection Station for Multi-Geometry Defect Detection
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Solution Overview
Problem
Existing optical inspection systems struggle to accommodate parts of varying sizes and geometries without reconfiguration, and they fail to accurately detect both dimensional and aesthetic defects using a single imaging setup.
Innovation Solution
A modular optical inspection station comprising a nest module, sensor module, and lighting modules that can be assembled into various configurations to accommodate parts of different sizes and geometries, using dark-field and bright-field lighting to capture images that enable accurate detection of defects through computer vision techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed imaging setup is used, then the system structure is simple, but it cannot accommodate parts of varying sizes and geometries
Solution Approach 1:
The inspection system is divided into modular components including sensor modules, lighting modules, and nest modules that can be independently configured and assembled. This segmentation allows the system to adapt to different part sizes and geometries by reconfiguring the arrangement of these modular elements without requiring complete system redesign.
Solution Approach 2:
The inspection station is designed with universal interfaces and standardized mounting mechanisms that allow the same hardware components to serve multiple inspection configurations. The system can inspect various part types using the same physical infrastructure, reducing complexity while maintaining versatility through software-controlled reconfiguration.
2Measurement precision
If a single imaging setup is used, then the device complexity is low, but it fails to detect both dimensional and aesthetic defects accurately
Solution Approach 1:
Multiple imaging capabilities are merged into a single integrated inspection station. The system combines dimensional measurement functions with aesthetic defect detection functions in one unified platform, allowing simultaneous execution of multiple inspection tasks without requiring separate standalone systems for each function.
Solution Approach 2:
The imaging setup employs dynamic adjustment mechanisms including adjustable lighting angles, movable camera positions, and reconfigurable nest arrangements. These dynamic elements allow the system to optimize its configuration for different inspection modes (dimensional vs. aesthetic) while maintaining a compact integrated structure.
3Measurement precision
If dark-field and bright-field lighting are used, then defect detection accuracy improves, but the system complexity increases
Solution Approach 1:
The lighting system operates in periodic cycles, alternating between dark-field and bright-field illumination modes based on the inspection requirements. This temporal separation allows the system to achieve high detection accuracy for different defect types without requiring all lighting elements to be active simultaneously, thereby managing complexity through time-multiplexed 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
Enables flexible and efficient optical inspection of parts with varying dimensions and geometries, providing accurate detection of both dimensional and aesthetic defects without requiring system reconfiguration, by utilizing multiple lighting modes and computer vision analysis.
Implementation Method 1
a directional light filter configured to pass light output by the dark-field light source substantially normal to the light plane, and configured to reject light output by the dark-field light source substantially nonparallel to the light plane
Implementation Method 2
an optical sensor defining a field of view directed toward the imaging volume
Data Source
AI summary
One variation of an optical inspection kit includes: an enclosure defining an imaging volume; an optical sensor adjacent the imaging volume and defining a field of view directed toward the imaging volume; a nest module defining a receptacle configured to locate a surface of interest on a first unit of a first part within the imaging volume at an image plane of the optical sensor; a dark-field lighting module adjacent and perpendicular to the nest module and including a dark-field light source configured to output light across a light plane and a directional light filter configured to pass light output by the dark-field light source normal to the light plane and to reject light output by the dark-field light source substantially nonparallel to the light plane; and a bright-field light source proximal the optical sensor and configured to output light toward the surface of interest.