Multi-Angle Camera Layout for Precise Product Defect Inspection
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Solution Overview
Problem
Existing inspection methods for selecting a defect of a product require a lot of manpower because an operator manually performs the inspection based on subjective recognition and judgment on a defect criterion with the naked eye, and have limitations when inspecting a large quantity of multi-variety products over a long period of time.
Innovation Solution
An apparatus utilizing a reference camera and a plurality of auxiliary cameras arranged symmetrically to capture objects at various angles, with a processor correcting auxiliary images based on a reference image to accurately detect defects such as appearance defects, fine scratches, or shape distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single camera is used for inspection, then the device complexity is low, but the measurement precision and defect detection capability are insufficient
Solution Approach 1:
The inspection system is segmented into multiple independent camera units, each capturing images from different directions (reference direction and multiple auxiliary directions). This segmentation allows each camera to focus on specific aspects of the product, improving overall detection precision while maintaining manageable complexity through modular design
Solution Approach 2:
The system transitions from single-dimension (single camera) inspection to multi-dimensional inspection by arranging cameras in three-dimensional space around the product. The auxiliary cameras are positioned at different heights and angles, creating a spatial array that captures the product from multiple perspectives simultaneously, thereby enhancing defect detection capability
2Reliability
If multiple cameras are arranged to capture various angles, then the defect detection accuracy improves, but the device complexity increases
Solution Approach 1:
The camera arrangement employs asymmetric positioning where the auxiliary cameras are not uniformly distributed but are strategically placed at specific heights and angles relative to the reference camera. This asymmetric arrangement optimizes coverage of critical inspection areas while reducing redundant camera positions, thereby improving reliability without proportionally increasing complexity
Solution Approach 2:
Each camera in the system is designed to serve multiple functions: the reference camera captures overall product appearance, while auxiliary cameras simultaneously capture side surfaces, top surfaces, and potential defect areas. This multi-functionality allows the system to achieve high inspection reliability with a relatively compact camera configuration
3Productivity
If manual inspection is used, then the equipment cost is low, but the productivity and inspection speed are limited
Solution Approach 1:
The system replaces manual mechanical inspection with an automated optical-mechanical system. Multiple cameras are positioned to capture product images from various angles simultaneously, and image processing algorithms automatically analyze the captured images to detect defects. This substitution dramatically increases inspection speed while the modular camera system keeps complexity manageable
Solution Approach 2:
The auxiliary cameras are pre-positioned to capture images of product surfaces that may contain defects before the product moves to the next inspection stage. This preliminary capture of potential defect areas allows for immediate automated analysis, increasing inspection speed without requiring complex real-time tracking systems
Data Source
AI summary
Disclosed is an apparatus for inspecting an appearance of a product. The apparatus may include: a reference camera for capturing an object in a reference direction; and a plurality of auxiliary cameras for capturing the object in a plurality of auxiliary directions different from the reference direction and the plurality of auxiliary cameras may be arranged in a shape in which the plurality of auxiliary cameras are symmetric to each other when projected onto a plane perpendicular to the reference direction.