Multi-color Surface Inspection via Wavelength-multiplexed Phase-shifting

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Solution Overview

Problem

Conventional white light phase-shifted deflectometry systems require a fixed spatial relationship between the illumination source, camera, and surface to be inspected, which is impractical for moving surfaces like painted auto bodies with unstable conveyance systems, leading to significant variations in image orientation and quality.

Innovation Solution

A multi-color system utilizing a multi-wavelength LED array that emits simultaneously phase-shifted spatial intensity color image patterns across different visible wavelength regimes, captured by a single wavelength-multiplexed sensor image, allowing for inspection without the need for fixed spatial alignment and enabling efficient defect detection on moving surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple sequential image acquisitions are used to inspect the surface, then measurement precision is improved, but loss of time increases and reliability deteriorates due to unstable spatial relationships during the acquisition period

Engineering Contradiction:
Improvesurface defect detection precisionVSAvoidtime for multiple image acquisitions
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent combines multiple phase-shifted spatial light intensity patterns into a single captured image by illuminating the surface with multiple wavelength regimes simultaneously. Each wavelength regime corresponds to a different phase shift, allowing the system to capture all phase information in one shot rather than requiring multiple sequential acquisitions. This merging of temporal sequences into a spatial multiplexing scheme resolves the contradiction by eliminating the time delay between acquisitions while maintaining the precision benefits of phase-shifting interferometry.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent transitions from temporal dimension (multiple sequential images taken at different times) to spatial dimension (multiple phase-shifted patterns encoded in different wavelength regimes captured simultaneously). By using wavelength-multiplexed illumination where each color channel represents a different phase shift, the system encodes what would traditionally require time separation into spatially distinguishable channels, thereby capturing all phase information in a single instantaneous capture.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Measurement precision

If multiple sequential image acquisitions are performed, then measurement precision is improved, but reliability worsens due to variations in image orientation from unstable conveyance systems

Engineering Contradiction:
Improvesurface property measurement precisionVSAvoidconsistency of image orientation
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent merges multiple phase-shifted measurements into a single captured image by using simultaneous multi-wavelength illumination. All phase-shifted spatial light intensity patterns are projected at the same moment across different wavelength regimes, and the camera captures them all in one exposure. This eliminates the temporal separation that causes orientation variations in sequential acquisitions, thereby maintaining measurement precision while improving reliability through consistent spatial relationships.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent adapts the traditional static phase-shifting approach (which assumes fixed spatial relationships) to a dynamic environment by making the illumination adaptive across wavelength regimes. Instead of requiring the entire system to be static, the system dynamically assigns different phase shifts to different wavelengths and captures them simultaneously, allowing the measurement to remain valid even when the object or camera moves during the capture process.

Inventive Principle:
Principle #15Dynamics

3Measurement precision

If fixed spatial relationship between illumination source, camera, and surface is maintained, then measurement precision is improved, but adaptability worsens for moving surfaces on unstable conveyance systems

Engineering Contradiction:
Improvesurface inspection precisionVSAvoidcapability to inspect moving surfaces
Core Design Contradiction:
Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent uses wavelength as an additional dimension to encode phase information, transitioning from a single spatial channel to multiple spectral channels. By projecting phase-shifted patterns at different wavelengths simultaneously and capturing them with a color camera, the system creates spectral-multiplexed measurements that are insensitive to spatial misalignment. This allows precise surface inspection of moving objects without requiring fixed spatial relationships between the illumination source, camera, and surface.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent changes the illumination parameter from monochromatic to multi-wavelength, where each wavelength regime carries a different phase shift. This parameter change allows the system to encode multiple measurements in parallel across the spectral domain, making the inspection process adaptable to moving surfaces while maintaining measurement precision through wavelength-based differentiation rather than temporal sequencing.

Inventive Principle:
Principle #35Parameter changes

4Loss of time

If single wavelength-multiplexed sensor image is used, then loss of time is reduced, but device complexity increases due to multi-wavelength illumination and wavelength-multiplexed sensing

Engineering Contradiction:
Improveacquisition time for surface inspectionVSAvoidcomplexity of multi-wavelength LED array and sensor system
Core Design Contradiction:
Loss of timeVSDevice complexity

Solution Approach 1:

The patent makes the single camera serve multiple functions by using its color sensing capability to detect multiple wavelength regimes simultaneously. Instead of requiring separate monochrome cameras for each phase shift, the system uses a standard color camera to capture all phase-encoded wavelength information in one shot. This multi-functionality approach reduces the number of required sensors while maintaining the time efficiency of single-shot acquisition.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses periodic phase-shifting patterns encoded in different wavelength regimes, where each color channel undergoes a cyclic phase variation. By synchronizing the illumination patterns across wavelengths and capturing them simultaneously, the system leverages the periodic nature of the phase shifts to extract surface information from the combined signal, reducing acquisition time while managing system complexity through coordinated temporal-spectral modulation.

Inventive Principle:
Principle #19Periodic action

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

The multi-color system effectively captures surface defects and properties with high sensitivity, reducing the need for multiple acquisitions and improving inspection efficiency on moving surfaces by utilizing a single wavelength-multiplexed sensor image, while minimizing positional repeatability issues.

Implementation Method 1

a multi-wavelength light-emitting diode (LED) array configured to illuminate the specimen with a multi-color light pattern

Methodology Applied
Scientific EffectLight Emitting Diode: Light Emitting Diode

Implementation Method 2

a multi-color sensor configured to capture each of the simultaneously emitted spatial intensity color image patterns reflected from the surface of the specimen

Methodology Applied
Scientific EffectPhotoelectric Effect: Photoelectric Effect

Implementation Method 3

phase-shifted deflectometry setup... The camera sequentially takes a plurality of images of the reflected pattern area... corresponding first and second areas in each of the simultaneously emitted spatial intensity color image patterns being phase-shifted relative to each other

Methodology Applied
Scientific EffectPhase Shift:

Data Source

PatentUS11994476B2Multi-color surface inspection system, method for inspecting a surface, and method for calibrating the multi-color surface inspection system
Publication Date: 2024.05.28 CARL ZEISS INDUSTRIELLE MESSTECHNIKE GMBH
  • US11994476B2 patent drawing
  • US11994476B2 patent drawing
  • US11994476B2 patent drawing

AI summary

A multi-color system for optically inspecting a surface of a specimen includes a multi-wavelength led array to illuminate the specimen with a multi-color light pattern including simultaneously emitted spatial intensity color image patterns, each of which has first areas in which light is emitted with a first light intensity and second areas in which the light is emitted with a second light intensity, the first light intensity being higher than the second light intensity, and corresponding first and second areas in each of the simultaneously emitted spatial intensity color image patterns being phase-shifted relative to each other. A multi-color sensor captures each of the simultaneously emitted spatial intensity color image patterns reflected from the surface of the specimen in a single wavelength-multiplexed sensor image, and a data processing apparatus in communication with the multi-color sensor determines properties of the surface based on an evaluation of the single wavelength-multiplexed sensor image.