Mold Surface Highlight Inspection for Small Scratch Detection
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Solution Overview
Problem
Current surface defect inspection methods for metal surfaces, such as contact type surface shape measuring devices and machine vision systems, face limitations in inspecting small size scratches and glossy surfaces, and are inefficient in terms of manpower and inspection time.
Innovation Solution
A mold surface inspection device that generates a reflective highlight on the surface of the inspection object using a light source with a 45° incident angle, images the highlight region, and processes the image to determine defects, allowing workers to assess the presence of defects based on the processed image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a machine vision system uses a CCD camera to receive diffused light on the surface, then the inspection process is automated, but small size scratches and processing marks cannot be detected and glossy surfaces cannot be inspected
Solution Approach 1:
The patent changes the lighting parameters by using a light source with a specific incident angle (45 degrees) to create specular highlights on the surface. This parameter change enables the detection system to capture reflected light that reveals small scratches and processing marks that are invisible under diffuse lighting conditions, thereby resolving the contradiction between automation and detection precision.
Solution Approach 2:
The patent introduces a vibration element that vibrates the inspection object during imaging. This vibration causes dynamic changes in the specular highlight patterns, making stationary defects like small scratches and processing marks visible as they interrupt the highlight continuity. This resolves the contradiction by enabling precise detection of minor defects while maintaining automated inspection.
2Measurement precision
If skilled workers directly investigate surface defects by hand and eye, then small defects can be detected, but the process takes a long time and generates inefficient manpower consumption
Solution Approach 1:
The patent replaces the mechanical human inspection system with an automated optical inspection system. The system uses a camera to capture images under controlled lighting conditions (45-degree incident angle creating specular highlights) and processes these images to detect surface defects. This substitution maintains high detection accuracy while dramatically improving inspection speed and eliminating manpower consumption, resolving the contradiction between precision and productivity.
3Measurement precision
If contact type surface shape measuring devices are used to measure surface roughness and waviness, then surface defects can be detected, but measurement is limited according to the size and shape of metal and inspection time increases
Solution Approach 1:
The patent replaces contact-type mechanical measuring devices with a non-contact optical inspection system. The system uses a camera to capture surface images under specific lighting conditions (45-degree incident angle) and processes these images to detect surface defects including roughness and waviness. This non-contact method eliminates the time-consuming nature of contact measurement while expanding applicability to various metal sizes and shapes, resolving the contradiction between measurement precision and inspection time.
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 efficient detection of surface defects, including small scratches and tool marks, on metal surfaces, improving inspection speed and accuracy compared to prior methods.
Implementation Method 1
a light source part configured to irradiate the inspection object with irradiated light so that a reflective highlight is generated on a surface of the inspection object
Data Source
AI summary
The present disclosure relates to a surface inspection method using a mold surface inspection device, and more specifically, to a surface inspection method using a mold surface inspection device including a setting part in which an inspection object is set, a light source part configured to irradiate the inspection object with irradiated light so that a reflective highlight is generated on a surface of the inspection object, an imaging part configured to image the surface of the inspection object so that a highlight region where a reflective highlight is generated is included, and an image processing part configured to process an image imaged in the imaging part to provide the image to a worker so that the worker determines whether defects are generated on the surface of the inspection object on the basis of the image.