Optical Sensor Edge Verification with Contrast Element
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Solution Overview
Problem
Existing light projection systems face challenges in verifying the position of components, such as sheet material in a layup, due to low contrast between the ply or layer and the underlying surface, often requiring manual verification by trained personnel.
Innovation Solution
An apparatus and method that utilize an optical sensor with a contrast element, such as a reflective material, to enhance the visibility of the component's edge by receiving and analyzing light reflected from the component and object, allowing for automated position verification using processors to determine edge position and detect foreign object debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light projection devices are used to verify component position, then automation and efficiency are improved, but verification accuracy deteriorates due to low contrast between component and underlying surface
Solution Approach 1:
A contrast element is introduced as an intermediary between the component edge and the optical sensor. This contrast element reflects light differently than the surrounding surface, creating a visible optical signature that enables the sensor to detect edge positions accurately even when the component itself provides low contrast against the background.
Solution Approach 2:
The contrast element changes the optical properties (reflectivity, color, or texture) at the component edge location. This creates a detectable difference in light reflection between the edge region and the surrounding surface, allowing the optical sensor to distinguish edge positions from the background with high precision.
2Measurement precision
If manual verification is used to achieve accurate detection, then measurement precision is improved, but productivity deteriorates due to reliance on trained personnel
Solution Approach 1:
The manual mechanical inspection process is replaced with an automated optical detection system. The optical sensor and contrast element system automatically detect edge positions and verify component placement, eliminating the need for trained personnel to manually inspect while maintaining or improving detection accuracy and increasing verification throughput.
Solution Approach 2:
The system enables self-verification where the component edge itself (enhanced with contrast element) serves as the detection target. The optical sensor automatically detects the contrast element's optical signature, allowing the system to verify its own measurements without human intervention, thereby improving both precision and productivity.
3Difficulty of detecting and measuring
If contrast element is added to enhance visibility, then detection capability is improved, but device complexity increases
Solution Approach 1:
The detection system is segmented into distinct functional components: the contrast element applied to the component edge, the optical sensor for detection, and the processor for analysis. This segmentation allows each component to be optimized independently and simplifies the overall system configuration by clearly defining the role of each element in the detection process.
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
Automated verification of component position improves accuracy and efficiency by enhancing contrast and enabling automated detection of edge positions and foreign objects, reducing reliance on manual inspection.
Implementation Method 1
an optical sensor configured to receive light reflected from the component and the object
Implementation Method 2
A contrast element disposed on or adjacent to the edge... allowing for automated position verification
Data Source
AI summary
An apparatus and method is provided for verifying the position of an edge of component on an object. The apparatus includes an optical sensor configured to receive light reflected from the component and the object. A contrast element disposed on or adjacent to the edge. One or more processors operably coupled to the optical sensor for determining the position of the edge at an inspection point. A system is also provided for cutting plies of a layup assembly and applying a contrast element to make the cut edge visible to position verification systems.