Automated Optical Inspection of Transmissible Components
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Solution Overview
Problem
The existing methods for inspecting light transmissible optical components, such as optical lenses, are labor-intensive, subjective, and prone to errors due to reliance on manual and visual checks, which can lead to inconsistent quality and increased risk of vision fatigue during mass production.
Innovation Solution
An automated inspection apparatus and method using an image capturing module and an adaptive illumination device with a spatial light modulator to capture bright field, dark field, or combined images of the optical component, enabling automatic defect identification through image analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual and visual checking methods are used for lens inspection, then the inspection process can be performed with simple equipment, but the inspection quality becomes subjective and inconsistent, and productivity is reduced due to time-consuming manual processes
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses a light source, imaging lens, and image sensor to capture and analyze lens images. The system substitutes human eyes and judgment with mechanical-optical-mechanical systems that provide objective, consistent, and repeatable inspection results, directly resolving the reliability and consistency issues of manual inspection
Solution Approach 2:
The inspection system automatically captures images, processes them through image processing algorithms, and identifies defects without requiring human intervention for each inspection cycle. The system performs self-evaluation by comparing captured images against defect criteria, enabling continuous automated operation that maintains consistent quality standards while improving productivity
2Productivity
If manual visual inspection is performed for extended periods, then the inspection process can continue without specialized equipment, but vision fatigue occurs leading to decreased inspection quality and potential eye damage
Solution Approach 1:
The patent replaces the human visual system with an automated optical imaging system consisting of a light source, imaging lens, and image sensor. This substitution eliminates exposure to harmful visual conditions while maintaining continuous inspection capability, as the mechanical system does not experience vision fatigue and can operate indefinitely without degradation in inspection quality
3Extent of automation
If reference images are used for defect identification, then automated defect detection can be achieved, but false defects may be identified due to limitations in reference image production
Solution Approach 1:
The system performs preliminary image processing and analysis to identify and filter out normal structural features before defect detection. By pre-processing images to remove known non-defect elements and establishing accurate baseline characteristics, the system reduces false positive identifications while maintaining automated detection capability
Solution Approach 2:
The inspection system incorporates feedback mechanisms where inspection results are continuously analyzed and used to refine detection algorithms. The system learns from identified defects and adjusts its criteria accordingly, reducing false defects over time while maintaining high automation levels. Feedback loops enable continuous improvement of detection accuracy
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 solution provides a reliable, objective, and efficient means to inspect optical components, reducing human error and fatigue, while enabling high-volume, automated detection of defects including anti-reflective coating issues with improved sensitivity and accuracy.
Implementation Method 1
an illumination device configured to shape light from a light source and to illuminate a selected portion of a surface of said light transmissible optical component with said shaped light
Data Source
AI summary
The invention provides an apparatus for inspecting a light transmissible optical component. The apparatus comprises an image capturing module arranged on a first side of a support configured to hold a light transmissible optical component whilst it is being inspected. The apparatus includes an illumination device configured to shape light from a light source and to illuminate a selected portion of a surface of said light transmissible optical component with said shaped light to enable the image capturing module to capture any of a bright field image, a dark field image, or a combined bright field and dark field image of the light transmissible optical component being held by the support.