Plane Light Source Detection for Uniform Product Quality Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing product quality detection systems using annular light sources suffer from non-uniform brightness and angle-dependent image capture issues, leading to inaccurate analysis when shooting angles shift, as the highlight position changes, affecting the reliability of product quality assessment.
Innovation Solution
A detection system employing a first light source with two parallel light emitting plates and a reflector plate to create a uniform plane light source, combined with a control module to manage image capture and analysis, ensuring consistent illumination and accurate image capture regardless of shooting angle shifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If an annular light source is used for illumination, then the illumination range is limited, but the brightness on different positions of the to-be-tested product becomes non-uniform
Solution Approach 1:
The annular light source is divided into multiple independent light emitting units (first light emitting unit, second light emitting unit, third light emitting unit, fourth light emitting unit) arranged around the optical axis. Each unit can be independently controlled, allowing selective illumination of different regions to achieve uniform overall illumination while expanding the effective illumination area.
Solution Approach 2:
Different light emitting units emit light with different characteristics tailored to their specific positions. The first and second light emitting units illuminate the first surface, while the third and fourth light emitting units illuminate the second surface. This local optimization ensures uniform brightness across the entire product surface by addressing each region's specific illumination needs.
2Measurement precision
If the shooting angle changes, then the highlight position of the image shifts, but the captured image is unable to acquire the correct information of the to-be-tested product
Solution Approach 1:
The detection system is designed with the optical axis of the imaging device passing through the center of the product opening, creating a symmetric illumination and detection configuration. This equipotential arrangement ensures that light paths and detection angles remain consistent regardless of minor angle variations, preventing highlight position shifts and maintaining accurate product information capture.
Solution Approach 2:
The control device coordinates the light emitting units and imaging device to maintain optimal illumination and detection geometry. By monitoring and adjusting the illumination configuration based on the product position, the system compensates for angle variations and ensures the highlight position remains stable for accurate measurement.
3Device complexity
If a single light source configuration is used, then the device structure is simple, but the illumination uniformity across the product surface is poor
Solution Approach 1:
The illumination system is segmented into multiple light emitting units with distinct functions. The first and second units provide primary illumination, while the third and fourth units provide supplementary illumination. This segmentation allows each unit to be optimized for its specific role, achieving superior overall illumination uniformity while maintaining reasonable structural complexity through modular design.
Solution Approach 2:
Multiple light emitting units are merged into a coordinated illumination system where their combined effect produces uniform illumination across the product surface. The control device merges the output of all light emitting units to create a balanced illumination pattern, achieving high illumination uniformity while sharing common structural components to minimize overall device complexity.
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
Ensures consistent and accurate image capture of product features, such as openings and labels, by maintaining uniform brightness across a wider area, reducing misjudgments and enhancing the reliability of product quality assessment.
Implementation Method 1
Each light emitting element emits light along a same direction
Implementation Method 2
The detection system includes a reflector plate
Data Source
AI summary
A detection system determines to-be-tested products to be qualified or not. The detection system includes a first detection module, a sensing module, and a control module. The first detection module includes a first photographing apparatus and a first light source. The first light source being a plane light source emits light and illuminates the to-be-tested product while the first photographing apparatus captures an image of the to-be-tested product. The control module controls the first light source to emit light and control the first photographing apparatus to capture the image of the to-be-tested product when receiving the sensing signal generated by the sensing module. The control module further analyzes the captured image for determining the to-be-tested product to be qualified or not.