Multispectral Light Assembly for Uniform Long-Distance Machine Vision
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Solution Overview
Problem
Conventional machine vision systems with multispectral light sources face inefficiencies due to the use of diffusers, which increase system size, reduce efficiency, and limit working distance, requiring numerous LEDs and simultaneous illumination to achieve color uniformity.
Innovation Solution
A compact illumination assembly using a plurality of multispectral light assemblies with light pipes, diffusive surfaces, and projection lenses, optimized for color mixing and uniformity, allowing direct light projection at extended distances with fewer LEDs and sequential activation of color channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If diffusers are used in conventional machine vision illumination systems, then color uniformity is achieved, but system size increases and working distance is limited
Solution Approach 1:
The patent removes the diffuser component from the illumination system entirely. Instead of using a diffuser to achieve color uniformity, the system employs individual LED modules with integrated phosphor layers that generate uniform spectral output inherently, eliminating the need for separate diffusing elements and reducing overall system size.
Solution Approach 2:
Each LED module serves multiple functions simultaneously: it provides structural support, generates light through LED emission, achieves color mixing through integrated phosphor conversion, and produces uniform illumination without requiring additional diffusing components. This multi-functionality consolidates what were previously separate components into a single integrated unit.
2Illumination intensity
If diffusers are used in conventional machine vision illumination systems, then color uniformity is achieved, but working distance is reduced
Solution Approach 1:
By removing the diffuser component, the optical path is shortened and working distance is extended. The LED modules with integrated phosphor layers produce uniform color output directly without requiring additional optical elements, thereby increasing the distance at which uniform illumination can be maintained.
3Illumination intensity
If numerous LEDs are used with simultaneous illumination, then color uniformity is achieved, but hardware complexity increases
Solution Approach 1:
The illumination system is divided into multiple independent LED modules, each containing a complete set of LEDs with integrated phosphor layers. Each module functions as a self-contained unit that produces uniform spectral output, allowing the system to achieve overall color uniformity through modular repetition rather than through complex control of numerous individual LEDs.
Solution Approach 2:
Each LED module integrates multiple functions: light generation, color mixing through phosphor conversion, and uniform illumination production. This consolidation reduces hardware complexity by eliminating the need for separate control systems for multiple LED types and removing diffuser components.
4Area of stationary object
If conventional illumination systems are used, then coverage area is achieved, but light distribution efficiency is reduced
Solution Approach 1:
The illumination system uses multiple discrete LED modules arranged to provide wide coverage. Each module efficiently directs light forward without the energy losses associated with diffusers, maintaining high light distribution efficiency while achieving broad area coverage through modular arrangement.
Solution Approach 2:
By removing diffusers from the system, light distribution efficiency is improved as direct LED illumination is used. The integrated phosphor layers within each module ensure uniform spectral output without the energy losses associated with traditional diffusing materials, maintaining both coverage area and efficiency.
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
Enables efficient, uniform illumination over a well-defined area at longer working distances with reduced hardware complexity and improved light distribution, enhancing the performance of machine vision systems in tasks like ID reading and inspection.
Implementation Method 1
a light pipe having an entrance surface and an exit surface and positioned in front of the multispectral light source, relative to an illumination direction, the light pipe configured to receive two or more of the plurality of different wavelengths of light generated by the multispectral light source and to provide color mixing for the two or more of the plurality of different wavelengths of light
Implementation Method 2
a diffusive surface on the exit surface of the light pipe and configured to receive color-mixed light transmitted from the light pipe
Data Source
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AI summary
A multispectral light assembly for an illumination system includes a multispectral light source configured to generate a plurality of different wavelengths of light and a light pipe positioned in front of the multispectral light source and configured to provide color mixing for two or more of the plurality of different wavelengths. The multispectral light assembly also includes a diffusive surface on the light pipe and a projection lens positioned in front of the diffusive surface. A processor device may be in communication with the multispectral light assemblies and may be configured to control activation of the multispectral light source.