Optical Inspection Path Planning for Complete Complex-Surface Coverage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical inspection methods struggle to perform comprehensive surface inspection of complex-shaped objects without overlooking any desired range, leading to potential oversight in flaw detection.
Innovation Solution
An optical inspection method involving a movable body with an illumination device and imaging device, utilizing path calculation to ensure complete coverage of the inspection area by calculating irradiation and imaging fields, and adjusting the positions and orientations of the illumination and imaging devices based on surface shape data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robot with a camera is moved to scan the surface of a complex-shaped object, then the inspection can cover the surface, but some desired ranges may be overlooked leading to incomplete inspection coverage
Solution Approach 1:
The patent performs preliminary path calculation processing before actual inspection by calculating irradiation field information based on the three-dimensional shape of the inspection target. This pre-calculated path ensures complete coverage of all desired ranges including recessed portions, preventing oversight during actual inspection while maintaining reliable and comprehensive inspection coverage.
Solution Approach 2:
The patent creates a virtual model of the inspection target's three-dimensional shape and calculates the irradiation field based on this copy. By using the shape data to simulate and determine the optimal illumination path in advance, the system ensures complete coverage without needing to physically test multiple paths, thus reducing device complexity while improving inspection reliability.
2Area of stationary object
If the illumination device is positioned to illuminate the entire surface, then coverage is improved, but the complexity of calculating the optimal path increases
Solution Approach 1:
The system performs preliminary calculation of the irradiation field based on the three-dimensional shape data of the inspection target before actual inspection. This pre-computation determines the optimal path that ensures complete area coverage including difficult-to-reach regions, while avoiding the need for complex real-time calculations during inspection execution.
Solution Approach 2:
The patent changes the approach from trial-and-error positioning to parameter-based calculation by using the three-dimensional shape parameters of the inspection target to directly compute the optimal illumination path. This transforms the problem from a complex spatial optimization challenge into a calculable parameter-based solution, reducing computational complexity while maximizing irradiation field coverage.
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
Ensures thorough optical inspection of complex surfaces without missing any desired range, enabling accurate detection of flaws by optimizing the path and positioning of illumination and imaging devices.
Implementation Method 1
irradiating the surface of the subject with a light beam from an illumination device
Data Source
AI summary
According to an embodiment, an optical inspection method includes calculating irradiation field information concerning an irradiation field on a surface of a subject when irradiating the surface of the subject with a light beam from an illumination device that is supported by a movable body and moved; and performing path calculation processing of calculating, based on the irradiation field information, a path for the illumination device to move.