Optical Inspection Layout With Mirrors for Compact Full-Surface Checks
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Solution Overview
Problem
Existing optical inspection machines for parts are large, costly, and complex due to the use of multiple viewing units and cameras, which complicates assembly, handling, and adaptation to different part shapes and dimensions.
Innovation Solution
An optical inspection machine with integrated surface and peripheral viewing units, using a reduced number of video cameras and mirrors, and a movable central mounting system for easy adaptation and adjustment to part geometry, allowing simultaneous inspection of all surfaces with a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple viewing units and video cameras are used to inspect all surfaces of a part, then image coverage and inspection quality are improved, but the overall size, cost, and complexity of the machine increase
Solution Approach 1:
The patent combines multiple viewing units (surface viewing unit and peripheral viewing unit) into a single integrated inspection station. The surface viewing unit with its video camera is positioned to inspect top and bottom surfaces, while the peripheral viewing unit with additional video cameras inspects side surfaces. All these viewing units are merged into one station that can inspect all surfaces of a part simultaneously or sequentially, reducing the need for multiple separate inspection stations and thereby reducing overall machine complexity while maintaining comprehensive image coverage.
Solution Approach 2:
The inspection station is designed with multi-functional viewing units that can inspect different surfaces of parts. The surface viewing unit can inspect both top and bottom surfaces by rotating the rotary table, and the peripheral viewing unit can inspect all side surfaces. This universal inspection capability allows a single station to perform multiple inspection functions that would otherwise require multiple dedicated stations, reducing device complexity while improving measurement precision.
2Measurement precision
If multiple viewing units and ejection stations are positioned with angular distance on the rotary table, then inspection quality is improved, but the machine's overall size and assembly complexity increase
Solution Approach 1:
The patent utilizes the vertical dimension and rotational dimension of the rotary table to position viewing units and ejection stations. Instead of spreading components horizontally across a large area, the inspection station is positioned at a specific angular location on the rotary table, and the viewing units are arranged vertically and radially within that station. The rotary table's rotation enables the same angular position to inspect multiple surfaces of the part, effectively using rotational movement to replace horizontal space, thereby reducing machine size while maintaining inspection quality.
3Device complexity
If a reduced number of viewing units and cameras are used, then machine size and cost are reduced, but the ability to acquire images of all surfaces is compromised
Solution Approach 1:
The patent employs dynamic elements including the rotation of the rotary table and the adjustable positioning of viewing units. The rotary table rotates to bring different surfaces of the part into the inspection position, allowing a reduced number of viewing units to capture images of all surfaces over time. Additionally, the viewing units can be adjusted in position and angle to optimize image acquisition for different part geometries. This dynamic adaptability compensates for the reduced number of components, maintaining comprehensive image acquisition capability while reducing device complexity.
4Measurement precision
If the machine is designed for high performance with multiple inspection stations, then image acquisition capability is improved, but assembly and handling become more difficult
Solution Approach 1:
The patent segments the inspection system into modular components: a surface viewing unit, a peripheral viewing unit, and an ejection station, all integrated into a single inspection station. Each viewing unit is a self-contained module with its own video camera and illumination system. This modular segmentation allows for easier assembly and maintenance compared to a fully integrated complex system, as individual modules can be assembled, tested, and replaced independently while maintaining high image acquisition capability.
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 machine achieves high-performance imaging with reduced size and cost, enabling easy adaptation to various part shapes and dimensions while maintaining image quality.
Implementation Method 1
a rotary table (10) on which parts (500) to be inspected are placed
Implementation Method 2
The viewing units use one or more video cameras, one or more illuminators to illuminate the parts being photographed
Implementation Method 3
one or more illuminators to illuminate the parts being photographed
Implementation Method 4
possibly a mirror system
Data Source
Figure 1
Figure 2~2a
Figure 3~7
AI summary
An optical inspection machine (1) for the quality control of parts, in particular gaskets, comprises a rotary table (10) on which the parts to be inspected are positioned and, above said rotary table (10), a peripheral viewing unit (14) suitable for inspecting the outer and/ or inner side surfaces of a part. The unit comprises a plurality of downward-facing video cameras and, beneath each video camera, at least one angled mirror suitable for reflecting the image of a portion of the outer and/or inner side surface of the part to be inspected.