Multi-Camera Side Vision for Fastener Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Contact-based technologies for inspecting screw heads are prone to wear, require specific skills for calibration, and have speed limitations, making them inefficient for high-speed fastener inspection in industries like automotive.
Innovation Solution
A quick inspection system using multiple side-view cameras positioned at 15° angles to capture rotated images of screw heads, allowing for accurate measurement without physical contact, integrated with image reflection means for compact design and precise interpolation of head size values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact-based technologies are used for inspecting screw heads, then measurement can be performed, but the technology is prone to wear, requires specific skills for calibration, and has speed limitations
Solution Approach 1:
The patent replaces contact-based mechanical measurement systems with a non-contact optical vision system. Multiple cameras capture images of screw heads from different angles, and image processing algorithms calculate dimensional measurements. This substitution eliminates mechanical wear, removes calibration skill requirements, and enables high-speed inspection to match production line speeds.
2Measurement precision
If multiple cameras are positioned at 15° angles to capture rotated images, then measurement accuracy reaches approximately 95%, but the device complexity increases
Solution Approach 1:
The patent uses multiple cameras positioned at different angular dimensions (15° intervals) to capture images of the screw head from various perspectives. This multi-dimensional imaging approach enables accurate calculation of head size parameters through image processing, achieving 95% measurement accuracy while managing system complexity through systematic camera arrangement.
3Ease of operation
If contact-based inspection methods are used, then inspection can be performed, but specific skills for calibration are required
Solution Approach 1:
The optical vision system performs self-calibration through image processing algorithms that automatically calculate dimensional measurements from captured images. The system uses known geometric relationships and image processing techniques to determine head sizes without requiring manual calibration by skilled operators, thereby improving ease of operation while maintaining inspection reliability.
4Reliability
If mechanical components are used for inspection, then measurement can be performed, but wear occurs reducing inspection reliability
Solution Approach 1:
The patent replaces mechanical inspection components with optical vision systems that use cameras and image processing. This eliminates physical contact between inspection tools and screw heads, preventing wear of mechanical components and extending system service life while maintaining or improving inspection reliability through consistent optical measurements.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A system of a series of fastening devices (1) having a head and a shank is described, the system comprising feeding means (2) with positioning means (3) of the series of fastening devices (1), at least one side vision apparatus (4) operable to capture at least one image of each fixing device (1) by means of at least one camera (5), (6), (7), (8), and an image analyzer (13). Also described is a side vision apparatus (4) consisting of a plurality of cameras (5), (6), (7), (8), in which each camera is aggregated with at least one image reflection medium (9), (10), (11), (12), to allow the simultaneous capture of a series of specifically oriented images of the same fixing device (1). Additionally, a quick inspection method of a series of fasteners is disclosed.