Multi-Camera Optical Defect Detection for Product Surfaces
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Solution Overview
Problem
In industrial production, detecting defects such as stair slope errors, scratches, sanding marks, and gas marks on product surfaces is challenging due to the complexity of surface geometries and variations, requiring an efficient optical detection method.
Innovation Solution
An electronic device equipped with multiple industrial cameras and adjustable light sources captures and analyzes images of product planes and edges using preset distances and angles, employing a neural network algorithm to identify defects, and a robot arm for comprehensive surface scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple cameras and light sources are used to detect defects on complex surfaces, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The detection system is segmented into multiple independent camera modules (first camera, second camera, third camera) each positioned at specific angles to capture different aspects of the product surface. Each camera is equipped with dedicated light sources, creating modular detection units that can be independently optimized and maintained while collectively achieving comprehensive defect detection on complex surfaces.
Solution Approach 2:
The system transitions from single-plane detection to multi-dimensional detection by positioning cameras at different spatial angles (front view, side view, and angled views). This multi-dimensional arrangement allows the system to detect defects on complex three-dimensional surfaces by capturing images from multiple perspectives, effectively adding spatial dimensions to the detection capability.
2Measurement precision
If comprehensive surface scanning is performed to detect all defects, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary action by capturing multiple images of the product surface simultaneously from different angles and lighting conditions. The first camera captures front view images, the second camera captures side view images, and the third camera captures angled view images all at once. This preliminary multi-angle capture eliminates the need for sequential scanning, reducing detection time while maintaining comprehensive defect detection accuracy.
Solution Approach 2:
The detection system maintains continuity of useful action by using multiple cameras operating simultaneously to capture the entire product surface in one detection cycle. Rather than sequentially scanning different areas, all cameras work in parallel to continuously capture images of different surface regions, ensuring no detection gaps while minimizing total detection time.
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
Effectively detects various defects on flat, edge, and 3D surfaces, enhancing quality control by revealing defects like gas marks, stair slope errors, and scratches with high precision and accuracy.
Implementation Method 1
detecting defects by capturing and analyzing images of the plane and the edges of the product
Data Source
AI summary
An electronic device for optically detecting an appearance of a product for defects includes a first camera device, a second camera device, at least one white light source, and at least one red light source. The first camera device is perpendicular to a plane of the product to be detected. When the red light source is activated, the first camera device captures images of edges of the plane of the product, when the white light source is activated, the second camera device captures images of the plane of the product. The electronic device detects the appearance of the plane of the product for defects according to the images captured by the first and second camera devices, the defects can include stair slope errors, scratches, sanding marks, and gas marks.