Automated Optical Inspection System Using Radiation Plane Scanning
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Solution Overview
Problem
Current automatic inspection systems for parts face limitations in accurately measuring geometric dimensions and generating calibration data, particularly when dealing with complex shapes and varying measurement conditions.
Innovation Solution
A system that uses an array of radiation planes to scan parts, with receivers measuring unobstructed planar portions of radiation to obtain measurement signals, and a stage subsystem for moving the radiation planes relative to the part, combined with linear sensors and electronics for processing these signals to generate calibration data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual gauging devices are used, then operation simplicity is maintained, but measurement precision and automation capability deteriorate
Solution Approach 1:
The patent replaces manual mechanical gauging devices with an automated optical measurement system that uses radiation planes (light sheets) to non-contactly measure geometric dimensions. The system employs radiation plane generators to create illuminated planes, detectors to capture reflected radiation, and automated processing to extract dimensional data, thereby eliminating manual operation while achieving high measurement precision through optical-photon interactions.
Solution Approach 2:
The patent introduces radiation planes (light sheets) as an intermediary between the measurement system and the part being inspected. These radiation planes serve as a mediating medium that interacts with the part surface, carrying information about geometric dimensions to the detectors without requiring direct physical contact or complex mechanical gauging mechanisms.
2Productivity
If automatic inspection systems are implemented, then productivity is improved, but measurement precision under varying conditions deteriorates
Solution Approach 1:
The patent implements feedback mechanisms where the measurement system continuously monitors radiation plane interactions with the part, and the processing system adjusts measurement parameters based on detected variations. This feedback loop compensates for changing measurement conditions such as part positioning variations, surface reflectivity differences, and environmental factors, maintaining measurement precision while enabling automated high-throughput inspection.
Solution Approach 2:
The patent employs dynamic adjustment capabilities in the automated inspection system, allowing measurement parameters (such as radiation plane position, angle, or intensity) to be adaptively changed during the inspection process. This dynamic flexibility enables the system to maintain measurement precision across varying production conditions while sustaining high productivity through automated operation.
3Adaptability or versatility
If complex shapes are inspected, then measurement comprehensiveness is improved, but difficulty of detecting and measuring increases
Solution Approach 1:
The patent uses radiation planes that provide multi-dimensional measurement capabilities by illuminating surfaces from multiple angles and positions. The system captures reflected radiation in three-dimensional space, enabling comprehensive inspection of complex shapes by analyzing spatial distribution of reflected light, thereby reducing measurement difficulty through dimensional enrichment of the measurement data.
Solution Approach 2:
The patent divides the inspection of complex shapes into multiple discrete measurement segments, where radiation planes systematically scan different portions of the part surface. The processing system reconstructs the complete geometric information by integrating these segmented measurements, making complex shape inspection more manageable and less difficult through systematic division of the measurement task.
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 precise and efficient inspection of parts by providing accurate geometric dimension measurements and calibration data, reducing the impact of time variations in measurement conditions and improving the accuracy of complex shape analysis.
Implementation Method 1
the part occludes each of the planes of radiation to create a corresponding array of unobstructed planar portions of the planes of radiation
Implementation Method 2
Each of the receivers measures the amount of radiation present in an adjacent pair of unobstructed planar portions created from the same plane of radiation to obtain at least one measurement signal
Data Source
AI summary
A method and system for automatically inspecting parts and for automatically generating calibration data for use in inspecting parts are provided. The system includes a support for supporting a part to be inspected and/or a calibration device along a measurement axis. The system further includes a head apparatus including a plurality of radiation plane generators for directing an array of planes of radiation at the part and/or device so that the part and/or device occludes each of the planes of radiation to create a corresponding array of unobstructed planar portions of the planes of radiation. Each of the unobstructed planar portions contains an amount of radiation which is representative of a respective geometric dimension of the part and/or device. The head apparatus further includes a plurality of radiation plane receivers or cameras such as line scan cameras. Each of the cameras measures the amount of radiation present in an adjacent pair of unobstructed planar portions created from the same plane of radiation to obtain at least one measurement signal. The system still further includes a stage subsystem including a stage movable along a stage axis substantially parallel to the measurement axis and coupled to the head apparatus to move therewith for translating the head apparatus relative to the part and/or device along the stage axis so that the planes of radiation scan the part and/or device supported by the support substantially perpendicular to the stage and measurement axes. The system may further include one or more mechanisms for reducing radiation cross talk between neighboring cameras.