Polarized Windshield Residue Detection for Factory Cleanliness Gating

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Solution Overview

Problem

Existing windshield residue detection methods are laborious, subjective, and inaccurate, making them sub-optimal for high-volume production and effective factory gating processes in automotive manufacturing.

Innovation Solution

A system utilizing polarized light and advanced computer vision algorithms to detect and quantify windshield residues, employing a light source assembly, camera assembly, and computing device to generate accurate cleanliness metrics through polarization imaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual inspection methods are used for windshield residue detection, then the system complexity is reduced, but the measurement precision and productivity deteriorate

Engineering Contradiction:

Improvesystem complexityVSAvoidcleanliness detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated optical measurement system. A polarized light source illuminates the windshield at specific angles (50-70 degrees), and a camera captures the reflected light to detect residues. This substitution of mechanical manual inspection with optical automation significantly improves measurement precision while maintaining acceptable system complexity through standardized optical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical parameter of light polarization to enhance detection capability. By using polarized light at specific angles and analyzing the degree and angle of polarization of reflected light, the system achieves superior residue detection accuracy. The computing device calculates polarization metrics that provide quantitative measures of cleanliness, improving measurement precision beyond manual inspection.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If manual inspection methods are used, then the device complexity is lower, but the productivity and reliability deteriorate

Engineering Contradiction:

Improveinspection system complexityVSAvoidwindshield inspection throughput

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces time-consuming manual inspection with automated optical imaging and computer vision algorithms. The system captures images of the entire windshield and processes them to identify residues, enabling rapid inspection of multiple windshields sequentially. This automation dramatically increases productivity while the standardized optical system ensures consistent reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates an optical copy (image) of the windshield surface using polarized light illumination and camera capture. This digital representation allows rapid processing and analysis of the entire surface without physical contact, enabling high-speed inspection comparable to automated manufacturing processes while maintaining detection accuracy.

Inventive Principle:

Principle #26Copying

3Device complexity

If manual inspection is used, then the system is simpler, but the reliability and objectivity of results deteriorate

Engineering Contradiction:

Improvedetection system complexityVSAvoidcleanliness assessment reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent uses polarized light at controlled angles (50-70 degrees) to create consistent optical conditions for reliable detection. The system measures the degree and angle of polarization as quantitative parameters that objectively indicate residue presence. This standardized physical measurement approach eliminates subjectivity and ensures reliable, repeatable results across different inspectors and conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The computing device processes the captured images by analyzing polarization characteristics and provides quantitative feedback on cleanliness status. The system calculates metrics based on polarization angle and degree, providing objective pass/fail determinations. This automated feedback mechanism ensures consistent and reliable assessment without the variability inherent in manual inspection.

Inventive Principle:

Principle #23Feedback

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

Enables reliable, repeatable, and efficient detection and quantification of windshield residues, facilitating high-volume production and effective factory gating processes.

Implementation Method 1

directing polarized light toward the windshield

Methodology Applied

Scientific EffectPolarization: Polarisation

Implementation Method 2

generating an image based on the polarized light reflected from the windshield

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentEP4671744A1System for windshield residue detection and quantification

Publication Date: 2025.12.31 TESLA INC

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AI summary

Some embodiments of the present disclosure relate to systems and methods for detecting and quantifying residues on a surface, such as a windshield, for a vehicle. In some embodiments, a system may include a light source assembly, a camera assembly, and a computing device. The light source assembly can direct a polarized light toward the surface. The camera assembly can capture the polarized light reflected from the surface to generate an image. The computing device can process the image to generate a processing result indicative of cleanliness of the surface.