Optical Inspection Tracking for Moving Conveyor-Line Defect Checks
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Solution Overview
Problem
Conventional methods for material testing in production or conveyor lines require objects to be stationary during inspection, limiting the number of checks that can be performed within the available cycle time, especially in modern production systems with short cycle times.
Innovation Solution
The method involves moving the object and the optical inspection device synchronously, allowing images to be taken during the movement, utilizing both standstill and conveying times to increase the number of checks without extending standstill times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the object is kept stationary during inspection, then the inspection accuracy is improved, but the productivity deteriorates due to limited standstill time in short cycle times
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a stationary inspection system to a moving inspection system. The optical inspection device is moved synchronously with the object during conveying, allowing inspection to occur throughout the entire conveying time rather than only during brief standstill periods. This dynamic approach enables multiple defect locations to be inspected within the same cycle time while maintaining inspection quality through synchronous movement and coordinated image capture.
2Productivity
If the optical inspection device is moved synchronously with the object, then the productivity is improved by utilizing conveying time, but the device complexity increases
Solution Approach 1:
The patent implements feedback by using a control device that receives conveying speed information from the production or conveyor line and automatically adjusts the movement of the optical inspection device to match. This closed-loop feedback system ensures synchronous movement without requiring complex mechanical synchronization mechanisms, as the inspection device's position is continuously adjusted based on real-time conveying speed data.
Solution Approach 2:
The control device acts as an intermediary between the conveyor line and the optical inspection device. It receives conveying parameters from the production line and translates them into corresponding movement commands for the inspection device, simplifying the overall system architecture by decoupling the mechanical synchronization requirements.
3Measurement precision
If multiple images are taken during movement, then the measurement precision is improved by examining multiple defect locations, but the loss of time increases due to additional imaging operations
Solution Approach 1:
The patent applies continuity of useful action by performing inspection operations continuously throughout the entire conveying time rather than during discrete standstill periods. Multiple images of different defect locations are captured in sequence during the object's movement, utilizing the full conveying time for productive inspection activities. This eliminates wasted time and enables comprehensive multi-location inspection within the same cycle 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
This approach enables multiple defect inspections (5 to 10 checks) within the same cycle time, compared to the conventional 1 or 2 checks, by leveraging both standstill and conveying times.
Implementation Method 1
at least one image (of the potential defect location) is taken by the inspection device at the potential defect location of the object
Data Source
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AI summary
The invention relates to a method for material testing of an object (2) in a production and/or conveyor line and an inspection apparatus (10) adapted for carrying out the material testing. During material testing, the object (2) is transported along a conveying direction (4) in a conveying plane (3) of a production and/or conveyor device (1), an optical inspection device (11) is positioned at at least one previously identified potential defect location (30) of the object (2) and at least one image is taken by the optical inspection device (11) at the potential defect location (30) of the object (2, 102). The object (2) is moved during the material testing, and the optical inspection device (11) is moved along with the object (2), the at least one image being taken by the optical inspection device (11) during the movement of the object (2, 102) and optical inspection device (11). (Fig. 1)