Optical Inspection Control Using 3D Object Models
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Solution Overview
Problem
Existing visual inspection systems in production require manual adjustment of camera positions and focal lengths, which is time-consuming and costly, and are not adaptable to changes in the product portfolio without hardware modifications.
Innovation Solution
A testing device with a camera and handling system controlled by a device that uses a 3D model of the object to position it within the camera's focal plane, allowing for versatile inspection without hardware changes, using a control device to manage the handling and lighting for high-quality image capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment of camera positions and focal lengths is performed, then image quality requirements are met, but time consumption and cost increase
Solution Approach 1:
The system performs self-adjustment through automatic object recognition and positioning. The control device automatically determines camera parameters and handling device positions based on object data, eliminating the need for manual intervention while maintaining image quality requirements
Solution Approach 2:
The system dynamically adjusts camera parameters (focal length, position) and handling device positions based on recognized object characteristics. Parameters are automatically modified according to object type, size, and inspection requirements, enabling adaptive optimization without manual adjustment
2Measurement precision
If fixed camera positions are defined for each product-specific inspection task, then inspection requirements are met, but adaptability to product portfolio changes decreases
Solution Approach 1:
The system transitions from static fixed camera positions to dynamic positioning. Camera parameters and handling device positions are automatically adjusted based on real-time object recognition and inspection requirements, enabling the system to adapt to different products without hardware modifications
Solution Approach 2:
The system is designed to handle multiple product types and inspection tasks using the same hardware configuration. Through automatic object recognition and parameter adjustment, a single inspection system can universally accommodate various products and inspection requirements without dedicated fixed setups for each product
3Stability of the object's composition
If mechanical fixing of camera parameters is performed, then system stability is improved, but later adjustments become complex and expensive
Solution Approach 1:
The system replaces mechanical adjustment mechanisms with software-based control. Instead of physically repositioning cameras or adjusting focal lengths mechanically, the system uses digital parameter modification and automated positioning control, simplifying adjustments while maintaining system stability
Solution Approach 2:
The system pre-stores optimal camera parameters and handling device positions for different object types. When an object is recognized, the system automatically retrieves and applies the pre-configured parameters, eliminating the need for complex real-time adjustments while maintaining inspection quality
Data Source
Figure 1
AI summary
Products of a production process are often subjected to a visual inspection. An inspection apparatus (1) for optically inspecting an object O is proposed, having a camera device, wherein the camera device (3) has a sharpness plane (10) with a recording region (11) and said camera device is embodied to record an image of the recording region (1), having a handling device (2) for gripping and/or receiving the object O, having a control device (13) for actuating the handling device (2), wherein the control device (13) is embodied to actuate the handling device (2) for the purposes of positioning the object O in the recording region (11), characterized in that the control device (13) comprises a model (15) of the object, wherein the control device (13) is embodied to actuate the handling device (2) for the purposes of positioning the object O in the recording region (11) on the basis of the (1) model (15).