Multi-Camera Inspection System Software Configuration
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Solution Overview
Problem
Advanced quality assurance techniques for camera-based inspection systems face challenges in simplifying hardware configurations and providing easy setup and monitoring in high-speed automation environments, where frequent changeovers and increased manufacturing demands complicate the implementation of automated quality inspection systems.
Innovation Solution
A video processing pipeline that utilizes containerized image analysis tools, including computer vision and machine learning algorithms, to generate quality assurance metrics and overlay images, which are then combined with object images to provide enhanced visuals for analysis, allowing for software-based configuration and visualization of inspection results, including anomaly detection and explainability of algorithm decisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple hardware components (triggers, lenses) are used for camera-based inspection, then inspection capability is improved, but system complexity increases
Solution Approach 1:
The patent replaces mechanical hardware components (triggers, lens changes) with software-based solutions. The system uses software-controlled camera modules that can dynamically adjust inspection parameters, generate synthetic triggers through image processing, and change optical characteristics via software-controlled mechanisms, thereby reducing physical hardware complexity while maintaining inspection capability.
Solution Approach 2:
The patent implements a universal camera module design that can perform multiple inspection functions through software configuration rather than requiring separate hardware for each function. The system can dynamically adapt the same physical camera module to different inspection tasks by changing software parameters, making the system multi-functional without increasing hardware complexity.
2Ease of operation
If hardware configuration is simplified, then ease of setup is improved, but inspection flexibility may be reduced
Solution Approach 1:
The patent implements dynamic software-based configuration that allows the inspection system to adapt to different inspection requirements without physical reconfiguration. The system can dynamically adjust inspection parameters, switch between different inspection modes, and modify camera module behavior through software, providing flexibility equivalent to hardware reconfiguration but with much easier setup.
Solution Approach 2:
The patent utilizes parameter changes in the software domain to achieve inspection flexibility. By modifying software-controlled parameters such as exposure settings, region of interest, inspection criteria, and processing algorithms, the system can adapt to different inspection scenarios without changing physical hardware configuration, thus maintaining flexibility while simplifying setup.
3Measurement precision
If more image analysis tools are added, then quality assurance capability is improved, but processing complexity increases
Solution Approach 1:
The patent segments the image analysis functionality into multiple specialized containerized tools, each performing a specific quality assurance function. These modular tools (e.g., defect detection, dimension measurement, surface inspection) can be independently developed, tested, and maintained, reducing overall processing complexity while providing comprehensive quality assurance capability through their coordinated operation.
Solution Approach 2:
The patent introduces a video processing pipeline as an intermediary layer that coordinates multiple containerized image analysis tools. This pipeline manages data flow between tools, standardizes interfaces, and orchestrates the complex processing sequence, thereby enabling sophisticated quality assurance analysis while keeping the system architecture manageable and complexity controlled.
Data Source
AI summary
Each of a plurality of co-located inspection camera modules captures raw images of objects passing in front of the co-located inspection camera modules which form part of a quality assurance inspection system. The inspection camera modules have either a different image sensor or lens focal properties and generate different feeds of raw images. The co-located inspection camera modules can be selectively switched amongst to activate the corresponding feed of raw images. The activated feed of raw images is provided to a consuming application or process for quality assurance analysis.