Multi-Directional Illumination for Component Insertion Inspection
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Solution Overview
Problem
Conventional inspection methods using digital images struggle to accurately determine the normalcy of component attachment based on the shape or position of the target object, leading to difficulties in assessing whether the attachment is good or bad.
Innovation Solution
An inspection device and method that utilize a plurality of light sources to illuminate a target object with holes and components from different directions, generating multiple digital images. The controller analyzes these images to determine if the components are normally inserted into the holes based on the shadows present in each image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single light source is used to illuminate the target object, then the inspection device is simple and easy to operate, but the accuracy of determining component attachment is insufficient
Solution Approach 1:
The patent applies dimensional change by transitioning from single-direction illumination to multi-directional illumination. Multiple light sources are positioned at different spatial angles around the target object, creating shadows that reveal component attachment status from multiple perspectives. This multi-dimensional lighting approach enables accurate detection of slanted or incomplete insertions that would be invisible from a single viewing angle.
2Reliability
If multiple light sources are positioned at different directions, then the detection accuracy of abnormal insertions is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent utilizes optical property changes, specifically shadow formation and light reflection variations, to detect attachment abnormalities. Different lighting angles create distinct shadow patterns and brightness variations that indicate proper or improper component insertion. The system analyzes these optical changes to determine attachment reliability without requiring complex mechanical sensors.
3Productivity
If conventional digital image inspection is used, then the inspection process is simple, but the ability to detect slanted or incomplete insertions is insufficient
Solution Approach 1:
The patent maintains automated digital image inspection for efficiency while adding multi-directional lighting to provide dimensional information. Multiple light sources create shadow patterns in captured images that reveal the three-dimensional status of component insertion. This allows the system to detect slanted or incomplete insertions through standard 2D image analysis, preserving productivity while dramatically improving detection precision.
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 approach significantly improves the accuracy of inspecting component attachment by enabling the detection of abnormalities such as slanted or incomplete insertions, which may be missed in unidirectional illumination methods.
Implementation Method 1
a plurality of light sources configured to illuminate an area including the hole in different directions in series
Data Source
AI summary
According to an embodiment, an inspection device inspects a target object including a hole and a component inserted into the hole. The inspection device includes a plurality of light sources configured to illuminate an area including the hole in different directions in series, a camera configured to generate a plurality of digital images of the area illuminated by the light sources in series, and a controller configured to determine whether the component is normally inserted into the hole based on a shadow included in each of the digital images generated by the camera.