Optical Inspection Device for 3D Surface Defect Detection
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Solution Overview
Problem
In industrial production, appearance checking of products for defects such as abnormal colors, stair slope errors, scratches, and sanding marks is inefficient, as existing methods lack precision and comprehensive coverage, particularly for complex surfaces like side surfaces and corners of electronic devices.
Innovation Solution
An electronic device equipped with a camera system, adjustable brackets, and multiple light sources captures and analyzes images of products using preset distances and angles, employing a neural network algorithm to detect defects, allowing for precise identification of defects on various surfaces, including side surfaces, corners, and 3D surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional appearance checking methods are used, then the checking process is simple, but the detection precision and comprehensive coverage are insufficient
Solution Approach 1:
The appearance checking system is segmented into multiple independent modules: camera module for image capture, light source module for illumination, bracket module for positioning, and neural network module for defect analysis. Each module performs a specific function, allowing the system to achieve high detection precision through specialized components while managing overall complexity through modular architecture.
Solution Approach 2:
The system transitions from traditional 2D surface inspection to 3D comprehensive inspection by adding vertical dimension with adjustable brackets and multiple light sources positioned at different heights and angles. This enables detection of defects on complex 3D surfaces including side surfaces, corners, and curved surfaces that cannot be captured by flat 2D inspection methods.
2Adaptability or versatility
If multiple light sources and adjustable brackets are added, then the coverage of complex surfaces is improved, but the device complexity increases
Solution Approach 1:
The bracket structure is designed as a universal adjustable platform that can position both camera and light sources at multiple predetermined locations. This multi-functional bracket serves as the foundation for achieving comprehensive surface coverage while avoiding the need for separate positioning mechanisms for each component, thereby managing structural complexity.
Solution Approach 2:
Multiple light sources are pre-positioned at predetermined locations on the bracket structure before inspection begins. The camera and light sources are pre-configured to capture images from multiple angles simultaneously, eliminating the need for complex real-time adjustment mechanisms during the inspection process and simplifying the overall device structure.
3Measurement precision
If neural network algorithm is used for analysis, then the defect detection accuracy is improved, but the processing time increases
Solution Approach 1:
The system captures multiple images from different angles and lighting conditions simultaneously in a single inspection cycle, preparing comprehensive image data in advance. This preliminary data collection allows the neural network to perform thorough analysis without requiring multiple sequential inspections, thereby reducing overall processing time while maintaining high accuracy.
Solution Approach 2:
The neural network algorithm continuously processes image data from multiple sources and angles simultaneously, maintaining constant analysis flow. The system processes all captured images through the neural network in an integrated manner rather than sequentially, ensuring continuous defect detection across all product surfaces without interruption or repeated processing cycles.
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 solution enables accurate detection of defects on complex surfaces, improving the efficiency and effectiveness of appearance checking by capturing detailed images and analyzing them with a neural network algorithm, ensuring thorough inspection and reducing human error.
Implementation Method 1
a camera device 20, a white light source 50 and a red light source 60... capture images of the sides and corners of the product
Data Source
AI summary
An electronic device for optically checking an appearance of products for defects includes a camera device, at least one white light source, and at least one red light source. The camera device is perpendicular to a side surface of a product to be checked, when the white light source is activated, the camera device captures images of the side surface and corners of the side surface of the product. When the red light source is activated, the camera device captures images of the side surface of the product. The electronic device checks for defects in appearance of the side surface of the product according to the images captured by the camera device, such defects including abnormal colors, stair slope errors, scratches, and sanding marks.