Optical Measurement System Threshold Core Processing

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Solution Overview

Problem

Existing optical measurement systems using white light in confocal systems face inefficiencies in light usage and struggle to accurately measure surface profiles with fine variations, particularly at boundaries between flat surfaces with different heights, due to indiscriminate averaging of measured values.

Innovation Solution

An optical measurement system employing a light source, optical system, spectroscope, light guide unit with multiple cores, and processing unit that separates reflected light into wavelength components, calculates distances for each core, and uses threshold values to differentiate between flat surfaces, allowing for accurate measurement by averaging distances based on these values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If white light is used in a confocal system, then the measurement can be performed in a noncontact manner, but light efficiency is lower than that in a triangulation system using a monochromic laser beam

Engineering Contradiction:
Improvesurface profile measurement capabilityVSAvoidlight efficiency
Core Design Contradiction:
Measurement precisionVSLoss of energy

Solution Approach 1:

The patent divides the white light into multiple wavelength components using a spectroscope, and assigns each wavelength component to a specific core in the light guide unit. This segmentation allows each core to transmit a specific wavelength range, improving light efficiency by eliminating the need to filter out unwanted wavelengths during transmission, while still enabling noncontact surface profile measurement.

Inventive Principle:
Principle #1Segmentation

2Productivity

If all measured values from multiple cores are indiscriminately averaged, then a single measured value is obtained, but measured values at positions where surface profile varies finely are smoothed and measurement accuracy is reduced

Engineering Contradiction:
Improvemeasurement acquisition speedVSAvoidsurface profile measurement accuracy
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies different processing methods to different groups of measured values based on their spatial distribution characteristics. When measured values from multiple cores are averaged, the system first determines whether the surface profile varies finely at each position. If fine variation is detected, the system processes each core's measured values separately rather than indiscriminately averaging them, thereby preserving local surface details while maintaining measurement efficiency.

Inventive Principle:
Principle #3Local quality

3Loss of energy

If multiple cores are used to increase light amount, then light efficiency improves, but the complexity of the optical system increases

Engineering Contradiction:
Improvelight efficiencyVSAvoidoptical system complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent merges multiple wavelength components into a single white light source, which is then distributed through a light guide unit containing multiple cores. Each core transmits a specific wavelength component, and all cores converge at the optical system. This merging approach increases light efficiency by utilizing all wavelength components simultaneously while managing system complexity through integrated optical path design.

Inventive Principle:
Principle #5Merging (Combining)

4Ease of manufacture

If measured values are averaged without threshold differentiation, then calculation is simplified, but rapid height changes at boundaries between flat surfaces cannot be accurately measured

Engineering Contradiction:
Improveprocessing simplicityVSAvoidboundary measurement accuracy
Core Design Contradiction:
Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent introduces a dynamic threshold differentiation mechanism that adapts to the specific characteristics of the measured surface. The system calculates threshold values based on the distribution of measured values from multiple cores, and dynamically determines which measured values should be averaged together and which should be processed separately. This dynamic approach maintains processing simplicity while enabling accurate measurement of rapid height changes at boundaries by identifying and preserving discontinuities in the surface profile.

Inventive Principle:
Principle #15Dynamics

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 measurement of surface profiles with multiple flat surfaces and rapid height changes by distinguishing between flat surfaces using threshold values, improving measurement accuracy and correcting for unevenness in measured positions.

Implementation Method 1

at least one spectroscope configured to separate the reflected light beams received by the optical system into wavelength components

Methodology Applied
Scientific EffectDispersion: Dispersion (of waves)

Implementation Method 2

a light guide unit configured to include a plurality of cores, to optically connect the light source and the optical system, and to optically connect the optical system and the spectroscope

Methodology Applied
Scientific EffectOptical conduction: Optical Fibre

Implementation Method 3

an optical system disposed to face an irradiation light beam from the light source and configured to irradiate a measurement object with the irradiation light beam and to receive a reflected light beam from a measuring surface of the measurement object

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentUS10794685B2Optical measurement system
Publication Date: 2020.10.06 OMRON CORP
  • US10794685B2 patent drawing
  • US10794685B2 patent drawing
  • US10794685B2 patent drawing

AI summary

An optical measurement system calculates a distance between an optical system and a measurement object based on reflected light beams corresponding to cores, compares a value indicating the distance with a threshold value for each of the reflected light beams, calculates an average value of all the values indicating the distance when the values in the reflected light beams corresponding to all the cores are equal to or greater than the threshold value or the values are less than the threshold value, and calculates an average value of the values indicating the distance which are equal to or greater than the threshold value or an average value of the values indicating the distance which are less than the threshold values when the values corresponding to some cores are equal to or greater than the threshold value and the values corresponding to the other cores are less than the threshold value.