Polarized Vision System for Package Seal Analysis
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Solution Overview
Problem
Automated systems face challenges in efficiently locating and analyzing specific areas of products or packages, particularly in applications where the orientation of packages varies, leading to inefficient resource utilization and potential faulty results.
Innovation Solution
A vision evaluation system comprising a light source with polarized backlight, a first camera with a 90-degree polarized filter, and a second camera, controlled by a system that takes simultaneous images to determine the location of select areas, such as seals, and analyze their integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated systems analyze all areas of packages, then product safety is improved, but resource waste increases on non-select areas
Solution Approach 1:
The system divides the package analysis into two distinct segments: first identifying the seal area using polarized light and the first camera, then analyzing only that specific seal area using the second camera. This segmentation allows the system to maintain high reliability for safety-critical seal analysis while avoiding waste of analysis resources on non-select areas of the package.
2Loss of energy
If automated systems analyze only select areas, then resource efficiency is improved, but measurement accuracy deteriorates due to difficulty locating select areas
Solution Approach 1:
The system utilizes polarized light interaction with the seal material to create a visually distinct appearance. The seal area diffuses polarized light differently than the rest of the package, making it appear distinct in the first camera's view. This optical property-based identification ensures accurate location of the seal area without resource waste, achieving both resource efficiency and measurement precision.
3Adaptability or versatility
If packages are oriented in different directions on conveyor, then system versatility is improved, but device complexity increases for locating select areas
Solution Approach 1:
The polarized light system creates an optical signature based on material properties rather than geometric orientation. Since the seal material's interaction with polarized light is intrinsic and orientation-independent, the system can identify seal areas accurately regardless of how packages are oriented on the conveyor, maintaining versatility without increasing complexity.
Solution Approach 2:
The system changes the parameter used for identification from geometric features (which would require complex orientation detection) to optical properties (polarized light diffusion). This parameter change makes the identification process invariant to package orientation, handling versatility while keeping the device relatively simple.
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
Effectively identifies and analyzes specific areas, ensuring accurate assessment and efficient processing by distinguishing the seal area through polarized light diffusion, thereby improving analysis efficiency and reducing faulty results.
Implementation Method 1
A ninety degree polarized filter is positioned between the first lens of the first camera and the light source. The ninety degree polarized filter is polarized 90 degrees from the polarized back light of the light source.
Implementation Method 2
the seal area is determined by analyzing image data from a first camera, wherein the first camera has a polarized filter that blocks polarized light from a light source, and the seal area diffuses the polarized light
Data Source
AI summary
Apparatus and methods of evaluating packages are provided. In a vision evaluation system embodiment, the system includes a light source, a first and second camera and a control system. The light source provides polarized backlight. The first camera has a first lens positioned to image the polarized back light. A ninety degree polarized filter is positioned between the first lens of the first camera and the light source. The ninety degree polarized filter is polarized 90 degrees from the polarized back light of the light source. The second camera has a second lens that is positioned near the first lens of the first camera. The control system is coupled to control the first and second cameras to take simultaneous images at a given frequency. The control system is further configured to determine locations to analyze based on image data from the first camera. Moreover, the control system is still further configured to analyze the determined locations in associated image data from the second camera. Packages whose image fails the analysis are removed from a packing line.