Multi-Spectral Imaging System for Surface Inspection
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Solution Overview
Problem
Existing surface inspection systems face challenges such as damage to inspected parts, limited data acquisition, high time consumption, and space inefficiency due to multiple cameras and light sources, which also lead to interference and reduced image quality.
Innovation Solution
A multi-spectral imaging system utilizing a single camera with a pair of sensors and a beam splitter to simultaneously capture 2-D and 3-D images using different wavelengths of light, allowing for adjustable sensor positioning to achieve focused images without the need for multiple cameras and light sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If multiple cameras and light sources are used to obtain both 2-D and 3-D images simultaneously, then image data completeness is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple light sources of different wavelengths and multiple sensors into a single integrated imaging system. A beam splitter directs different wavelengths to different sensors within one camera assembly, enabling simultaneous 2-D and 3-D imaging without requiring separate cameras and light sources for each function.
Solution Approach 2:
The imaging system is designed to perform multiple functions using a single camera assembly. The same optical path and lens serve both 2-D imaging (via one sensor) and 3-D imaging (via another sensor), making the system universal rather than requiring specialized equipment for each imaging type.
2Measurement precision
If multiple light sources are used to illuminate the surface, then image quality is improved, but light interference increases
Solution Approach 1:
The patent segments the light paths using a beam splitter that separates different wavelengths. Each wavelength from different light sources is directed to a dedicated sensor, preventing interference between light sources while maintaining the benefits of multi-wavelength illumination for enhanced image quality.
Solution Approach 2:
The beam splitter acts as an intermediary element that mediates between multiple light sources and multiple sensors. It selectively directs specific wavelengths to specific sensors, enabling multiple light sources to work together without interfering with each other, thus maintaining high image quality.
3Device complexity
If separate images are obtained at separate times using a single camera, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The patent enables continuous simultaneous capture of both 2-D and 3-D images through a single camera assembly with multiple sensors. Both image types are acquired at the same time during one exposure event, eliminating the need for sequential imaging and thereby maintaining high inspection productivity while using a unified device.
4Measurement precision
If a stylus-based measurement system is used, then measurement precision is improved, but the inspected surface may be damaged
Solution Approach 1:
The patent replaces mechanical contact-based stylus measurement systems with a non-contact optical imaging system. Multiple wavelengths of light are used to capture surface information without physical contact, thereby eliminating the risk of surface damage while maintaining measurement precision through advanced optical detection methods.
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 enables efficient, non-destructive inspection of surfaces with enhanced data acquisition, reduced space requirements, and improved image quality by generating separate images of surface features and height dimensions simultaneously, while allowing for movement of the inspected part.
Implementation Method 1
the beam splitter allows one of the first light or the second light to pass through the beam splitter, and the other of the first light or the second light to be reflected off the beam splitter
Implementation Method 2
refracting the other of the first or second wavelength of light through the beam splitter within the camera and onto a second sensor different from the first sensor
Implementation Method 3
The lens is configured to focus the first and second wavelengths onto their respective sensors
Data Source
AI summary
A multi-spectral imaging system includes a first light source that emits a first wavelength and a second light source that emits a second wavelength different than the first wavelength. The system further includes a camera having a lens, a beam splitter downstream of the lens and a pair of sensors downstream of the beam splitter. The lens is configured to focus the first and second wavelengths onto separate ones of the sensors, and the beam splitter allows one of the first wavelength or the second wavelength to pass through the beam splitter, and the other of the first wavelength or the second wavelength to be reflected off the beam splitter. One of the pair of sensors is configured to receive the first wavelength to produce a first image and the other of the sensors is configured to receive the second wavelength to produce a second image different from the first image.