Multi-Angle Optical Grading System for Color and Defect Detection
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Solution Overview
Problem
Current optical grading systems face challenges in accurately grading objects with irregular shapes and varying colors due to limitations in multi-reflection and multi-angle views, leading to inefficiencies in detecting surface defects and color variations, especially when objects are conveyed at high speeds or have complex shapes.
Innovation Solution
A novel color-based optical grading system with multiple advanced optics units, each comprising programmable cameras, spectral light sources, adjustable mirrors/prisms, and a backlighting dome, controlled by a master controller to analyze objects from multiple angles and reflections, ensuring comprehensive grading of objects on transparent conveyor surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single camera and light source are used to capture objects on a conveyor, then the device complexity is reduced, but the measurement precision and reliability of color grading deteriorate due to inability to view objects from multiple angles
Solution Approach 1:
The optical grading system is divided into multiple independent optics units, each equipped with its own camera and light source. Each unit captures images from a specific angle, and the results are integrated to form a comprehensive grading decision. This segmentation allows the system to maintain high measurement precision across multiple viewing angles while keeping each individual optics unit relatively simple in structure.
Solution Approach 2:
The system transitions from a single 2D top-view capture to multi-dimensional imaging by arranging multiple optics units at different angles (including side views and inverted views). This dimensional expansion enables comprehensive inspection of irregularly shaped objects from all surfaces, significantly improving color grading accuracy for objects with complex geometries.
2Productivity
If objects are conveyed at high speed on a moving conveyor, then the productivity is improved, but the measurement precision deteriorates due to variations in viewing distance and angle causing inconsistent signals
Solution Approach 1:
Multiple optics units are pre-positioned at fixed angles and locations along the conveyor path. The system captures images at multiple predetermined viewpoints simultaneously as objects pass through, eliminating the need for sequential imaging. This preliminary arrangement of multiple capture points ensures consistent measurement precision even at high conveyor speeds.
Solution Approach 2:
The system merges multiple image captures from different optics units into a single comprehensive grading decision. By combining the data from top-view, side-view, and inverted-view cameras, the system achieves robust color variation detection that is insensitive to conveyor speed fluctuations or minor positioning variations.
3Device complexity
If only top view imaging is used for irregularly shaped objects, then the device complexity is reduced, but the measurement precision deteriorates due to inability to detect surface defects on hidden surfaces
Solution Approach 1:
The imaging system is segmented into multiple optics units positioned at different locations: above the conveyor for top views, beside the conveyor for side views, and below the conveyor for inverted views. Each segment captures a specific portion of the object's surface, and together they provide complete coverage of all surfaces including hidden areas of irregularly shaped objects.
Solution Approach 2:
The system moves beyond 2D top-down imaging by incorporating side-view and bottom-view cameras positioned at different spatial dimensions. This multi-dimensional imaging arrangement enables detection of surface defects on all surfaces of irregular objects, including those not visible from the top, thereby significantly improving measurement precision.
4Measurement precision
If multiple optics units with multi-angle views are implemented, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
Each optics unit is designed as a universal module capable of capturing images at its designated angle with standardized components (camera, light source, housing). This modular universality allows the system to achieve high measurement precision through multiple views while controlling overall complexity by using repeated, standardized units rather than custom-designed complex systems.
Solution Approach 2:
The master controller serves as an intermediary that receives images from multiple optics units, processes the data, and integrates the results into a final grading decision. This centralized intermediary simplifies the system architecture by providing a single point of coordination, reducing the complexity that would otherwise arise from managing multiple independent processing units.
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
This system enables accurate, efficient grading of objects into multiple grades in a single pass, improving the detection of color variations and surface defects, enhancing the grading process by providing detailed multi-reflection and multi-angle views, thus increasing the efficiency and accuracy of the grading machine.
Implementation Method 1
color and intensity of light reflected from a single object
Implementation Method 2
programmable cameras... to analyze objects from multiple angles and reflections
Data Source
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AI summary
The present invention discloses a novel color based optical grading system with multi-reflectance and multi-angle views for grading objects of different external characteristics, and a novel color based optical grading method for grading objects based on different external characteristics. The system comprises of: multiple advanced optics units and at least one master controller. Each optics unit comprises of multiple programmable cameras, multiple spectral light sources, multiple adjustable mirrors/prisms, a mirror/prism adjustment assembly to ensure the enhanced surface analysis of the objects; at least one backlighting domes to provide uniform backlight for capturing objects in multi-reflection and multi-angle views and at least one image processing unit for processing images of each objects. The system is capable of not only identifying the type or color grade of individual object with enhanced accuracy, but is also efficient in analyzing different objects based on external characteristics like different sized objects are analyzed due to functioning of multiple adjustable mirrors or prisms. The system is automated and accurate color grading system which is capable of not only analyzing all possible color variations of any object, but is also capable of analyzing all other possible external characteristics.