Moving Object Surface Inspection With Synchronized Imaging
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Solution Overview
Problem
Existing object inspection systems require objects to be stationary, have a large footprint, necessitate recalibration for different colors and ambient light changes, and are prone to false positives, thereby reducing manufacturing efficiency and increasing costs.
Innovation Solution
An object inspection system with fixed lights and cameras that capture images of moving objects, using a processing assembly to detect defects, and an automated correction assembly to address defects in real-time without stopping the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior camera and computer based inspection systems are used, then defect detection capability is improved, but manufacturing efficiency deteriorates due to requiring objects to be stopped or remain stationary
Solution Approach 1:
The inspection system transitions from a static configuration where objects must be stationary to a dynamic configuration where the inspection apparatus moves with the object on the conveyor. The camera and light source are positioned to move in synchronization with the object, enabling continuous inspection without stopping the manufacturing process, thus resolving the contradiction between defect detection reliability and manufacturing efficiency
Solution Approach 2:
A conveyor system acts as an intermediary mechanism that carries both the object and the inspection apparatus together through the inspection zone. This intermediary enables the object to remain in motion while still allowing the camera to capture images at the correct moment, thereby maintaining both productivity and defect detection capability
2Reliability
If prior inspection systems with moving lights are used, then defect detection is achieved, but safety hazards increase due to moving lights near the manufacturing process
Solution Approach 1:
The light source is configured to move synchronously with the object on the conveyor rather than moving independently near the manufacturing process. This dynamic positioning keeps the light source at a safe, consistent distance from the object throughout the inspection process, eliminating safety hazards while maintaining defect detection capability
3Reliability
If prior inspection systems are used, then defect detection capability is improved, but device footprint increases requiring relatively large manufacturing space
Solution Approach 1:
The inspection apparatus components (camera, light source, and positioning mechanism) are merged into a single integrated unit that moves with the object on the conveyor. This consolidation eliminates the need for separate stationary inspection stations and reduces the overall device footprint while maintaining defect detection capability
Solution Approach 2:
The inspection system uses dynamic positioning where the camera and light source move with the object rather than requiring large stationary structures. This approach significantly reduces the space required for the inspection device while maintaining the ability to detect defects on moving objects
4Reliability
If prior inspection systems are used, then defect detection is achieved, but recalibration frequency increases due to ambient light changes and different paint colors
Solution Approach 1:
The light source uses a specific wavelength (e.g., ultraviolet or infrared) that is independent of ambient visible light conditions. This parameter change in the illumination wavelength makes the inspection system insensitive to ambient light changes and different paint colors, eliminating the need for frequent recalibration while maintaining defect detection reliability
Data Source
AI summary
An object inspection system and a method for detecting defects which utilizes a plurality of cameras and lights to capture images of a portion of an object and which uses the captured images to determine the presence of a defect upon a surface, such as surface, of the object and which may communicated the location of the identified defect to an automated defect repair assembly.