360° Optical Inspection of Parts Using Multi-Angle Illumination

Solution Overview

Problem

Current automatic inspection methods for parts, such as ammunition cases and threaded fasteners, are inefficient in detecting defects on outer peripheral surfaces, particularly cracks and splits, which can lead to quality control issues and increased manufacturing time due to the need for part rotation during inspection.

Innovation Solution

A high-speed, compact system that uses multiple angularly spaced radiation sources to illuminate the outer peripheral surfaces of parts, forming a continuous 360° panoramic composite image, allowing for simultaneous detection of defects like dents, splits, and thread profile parameters without requiring part rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional inspection methods rotate parts during inspection, then complete surface coverage is achieved, but inspection time increases and productivity decreases

Engineering Contradiction:

Improvesurface defect detection accuracyVSAvoidinspection speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The inspection system divides the 360-degree peripheral surface into multiple angular segments, with each radiation source illuminating a specific angular range. Multiple detectors simultaneously capture images of different segments, eliminating the need for sequential part rotation while achieving complete surface coverage through parallel multi-angle imaging.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from sequential temporal inspection (rotation over time) to simultaneous spatial inspection by arranging radiation sources and detectors in angularly spaced configurations around the part, capturing the entire peripheral surface in a single stationary inspection cycle.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If multiple radiation sources are used to illuminate all surfaces simultaneously, then inspection time is reduced, but system complexity and cost increase

Engineering Contradiction:

Improveinspection speedVSAvoidnumber of radiation sources and detectors

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each radiation source-detector pair is designed to be multifunctional, capable of inspecting different angular segments of the part perimeter. The modular angularly spaced configuration allows the same basic inspection unit to cover multiple surfaces by strategic positioning, reducing the total number of components needed compared to a fully redundant system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of time

If part rotation is eliminated, then manufacturing time is reduced, but complete coverage of outer peripheral surfaces becomes difficult

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoidsurface coverage completeness

Core Design Contradiction:

Loss of timeVSMeasurement precision

Solution Approach 1:

The inspection system divides the 360-degree peripheral surface into multiple angular segments, with each radiation source illuminating a specific angular range. Multiple detectors simultaneously capture images of different segments, eliminating the need for sequential part rotation while achieving complete surface coverage through parallel multi-angle imaging.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from sequential temporal inspection (rotation over time) to simultaneous spatial inspection by arranging radiation sources and detectors in angularly spaced configurations around the part, capturing the entire peripheral surface in a single stationary inspection cycle.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables rapid and accurate inspection of parts, reducing manufacturing time and improving quality control by providing seamless 360° imaging and defect identification, including thread defects, without the need for part rotation, thus enhancing the efficiency and reliability of the inspection process.

Implementation Method 1

energizing the radiation sources so that the radiation sources simultaneously illuminate a plurality of exterior side surfaces of the part... to obtain corresponding reflected radiation signals

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9047657B2Method and system for optically inspecting outer peripheral surfaces of parts

Publication Date: 2015.06.02 GII ACQUISITION LLC DBA GENERAL INSPECTION

AI summary

A method and system for optically inspecting the entire outer peripheral surface of a part are provided. The system includes an enclosure which allows movement of a part relative to the enclosure both prior to and after inspection within the enclosure. An illumination assembly simultaneously illuminates a plurality of exterior side surfaces of the part which are annularly spaced about the axis of the part with radiation when the part is at a predetermined location within the enclosure to obtain corresponding reflected radiation signals. A plurality of lens and detector assemblies are provided. Each of the assemblies forms an optical image of one of the illuminated exterior side surfaces from the reflected radiation signals and detects the formed optical image within the enclosure. A processor processes the detected optical images to obtain a continuous, seamless, 360° panoramic composite image of the peripheral surface of the part.