Molded Product Surface Defect Inspection Using Adaptive Imaging
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Solution Overview
Problem
Current quality inspection of molded product surfaces in factories is subjective and prone to errors, leading to damage in subsequent processes due to missed defects.
Innovation Solution
A molded product surface defect measuring apparatus and method using a sensor module, lighting module, and camera module controlled by a processor to objectively inspect surfaces through data analysis, adjusting focus and brightness for clear defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by workers is used to determine surface defects, then the inspection method is simple and requires minimal equipment, but the determination is subjective and leads to errors causing damage in subsequent processes
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated optical inspection system comprising a camera module, lighting module, and processor. The camera captures images of the molded product surface, the lighting module illuminates the surface, and the processor automatically analyzes the images to detect defects such as scratches and dents, eliminating subjective human judgment.
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the molded product and the inspection decision. The camera module captures surface images, which are then processed by the processor to objectively identify defects. This intermediary system provides consistent, repeatable measurements不受 worker fatigue or subjective judgment影响.
2Reliability
If automated optical inspection system is implemented, then objective and accurate defect measurement is achieved, but the device complexity and initial investment increase
Solution Approach 1:
The patent designs a multi-functional inspection system where a single integrated apparatus performs multiple functions: the camera module captures images, the lighting module provides illumination, the sensor module detects door closing/opening events, and the processor coordinates all operations and performs image analysis. This universal system handles various defect types (scratches, dents, etc.) on different molded products through a unified platform.
Solution Approach 2:
The inspection system is designed to operate autonomously without continuous human intervention. The sensor module automatically detects when a molded product is placed in the inspection apparatus by sensing door closing events, triggering the lighting and camera operations automatically. The processor independently analyzes captured images and generates inspection results, making the system self-sufficient once deployed.
3Measurement precision
If multiple camera modules and lighting modules are used to capture clear surface images, then defect detection accuracy improves, but the manufacturing cost and device complexity increase
Solution Approach 1:
The patent employs multiple lighting modules positioned at different locations around the molded product, with each lighting module targeting specific surface areas. Similarly, multiple camera modules are strategically positioned to capture different regions of the product surface. This local optimization ensures that each component focuses on its designated area, providing comprehensive coverage without unnecessary redundancy.
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 objective and efficient detection of defects, reducing human error and improving productivity by allowing rapid, accurate identification of surface abnormalities.
Implementation Method 1
a lighting module configured to emit light required for measuring a defect in a surface of a molded product
Implementation Method 2
a camera module configured to photograph the surface of the molded product
Data Source
AI summary
The present invention relates to a molded product surface defect measuring apparatus, which includes a sensor module configured to detect a signal for performing a door closing/opening event or a lighting-on/off event of the molded product surface defect measuring apparatus, a lighting module configured to emit light required for measuring a defect in a surface of a molded product, a camera module configured to photograph the surface of the molded product, and a processor configured to control the lighting module and the camera module to perform the measuring of the defect in the surface of the molded product.