Paint Surface Measurement With Dual Diffusers and Light Shield
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Solution Overview
Problem
Existing inspection devices for car paint surfaces face challenges in maintaining uniformity in illumination patterns, leading to measurement variations and inaccurate defect detection due to non-uniform illumination at the ends of linear light sources.
Innovation Solution
A measuring apparatus with a configuration that includes an illuminator, first and second diffuser plates, and a light shield portion to form a uniform illumination pattern, using a combination of point light sources and diffuser plates to ensure consistent light distribution and accurate defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple linear light sources are arranged in an array direction to illuminate the object, then the illumination coverage is improved, but the uniformity of illumination pattern deteriorates at both ends of the linear light sources
Solution Approach 1:
A diffuser plate is introduced as an intermediary component between the multiple linear light sources and the object to be measured. The diffuser plate scatters and redistributes the light from the array of linear light sources, transforming the non-uniform illumination pattern (with bright ends and dim center) into a uniform illumination pattern across the entire measurement area, thereby resolving the contradiction between coverage and uniformity
Solution Approach 2:
The optical properties of the illumination system are changed by introducing a diffuser plate that modifies the light distribution parameters. The diffuser plate changes the intensity distribution profile from a peaked ends pattern to a uniform pattern, effectively altering the illumination parameters to achieve both wide coverage and high uniformity
2Device complexity
If non-uniform illumination pattern is used, then the device complexity is reduced, but the measurement precision deteriorates due to measurement variations
Solution Approach 1:
The diffuser plate serves as a simple intermediary component that achieves uniform illumination without requiring complex control systems or multiple light source adjustments. This maintains device simplicity while dramatically improving measurement precision by eliminating illumination-induced measurement variations
Solution Approach 2:
By changing the illumination uniformity parameter through the diffuser plate, the system achieves high measurement precision without increasing device complexity. The diffuser plate is a passive optical element that modifies light distribution parameters to match the measurement requirements
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 achieves highly accurate measurement and defect detection on painted surfaces by ensuring uniform illumination patterns, reducing measurement variations and enhancing the precision of defect identification.
Implementation Method 1
a first diffuser plate, a second diffuser plate between the first diffuser plate and the object
Implementation Method 2
a light shield portion between the second diffuser plate and the object and having an opening that includes an optical axis of light emitted from the light source
Implementation Method 3
a light receiver to receive light specularly reflected from the object illuminated by the illuminator
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A measuring apparatus includes an illuminator (11) including a light source (13) to emit light onto an object (2) being conveyed in a conveyance direction; a first diffuser plate (14); a second diffuser plate (15) between the first diffuser plate (14) and the object; a light shield portion (16) between the second diffuser plate (15) and the object; and a light receiver (12) to receive light specularly reflected from the object illuminated by the illuminator (11). The light shield portion has an opening (17) that includes an optical axis of light emitted from the light source and reaching the second diffuser plate (15).