Prism-Based Multi-Surface Inspection for High-Resolution Imaging
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Solution Overview
Problem
Existing multiple surface inspection systems require components to be placed within inspection equipment, resulting in low resolution and the need for different image data generation systems with varying focal lengths, as image data from different surfaces is not in the same focal plane and is contained within a larger area than the component's surface area.
Innovation Solution
A system utilizing a prism with two reflecting surfaces that compensates for focal length differences, allowing a single set of image data to be generated from multiple surfaces, including a top and side surface, without the need for axial movement of the component, using a pick and place tool or conveyor to move inspection pieces past the prism, ensuring high-resolution imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single set of image data is used to inspect multiple surfaces, then inspection efficiency is improved, but the image data cannot be captured with high resolution because the surfaces are not in the same focal plane
Solution Approach 1:
A prism is introduced as an intermediary optical element between the inspection piece and the image data generation system. The prism reflects light from different surfaces (top and side surfaces) into the same focal plane, enabling a single image data set to capture multiple surfaces with high resolution. This mediator resolves the focal plane mismatch without requiring multiple inspection systems.
2Measurement precision
If the inspection piece is placed within the inspection apparatus, then multiple surfaces can be inspected, but the component must be axially moved into position which reduces inspection efficiency
Solution Approach 1:
Instead of moving the inspection piece axially into the inspection apparatus, the system inverts the approach by using optical reflection to bring multiple surfaces into the focal plane of a stationary image data generation system. The prism reflects light from both top and side surfaces simultaneously, eliminating the need for axial movement of the component while maintaining multi-surface inspection capability.
3Measurement precision
If different image data generation systems with different focal lengths are used, then each surface can be inspected, but the system complexity increases and resolution decreases
Solution Approach 1:
A single image data generation system is designed to inspect multiple surfaces by using a prism that redirects light from both top and side surfaces into the same focal plane. This universal system eliminates the need for multiple specialized inspection systems with different focal lengths, reducing complexity while maintaining high resolution across all inspected surfaces.
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
This approach enables high-resolution image data capture of multiple surfaces with a single set of image data, increasing pixel density and reducing the need for multiple focal lengths, allowing for continuous on-the-fly inspection without axial movement of inspection pieces, thereby improving inspection efficiency and accuracy.
Implementation Method 1
a prism having a first end, a second end, a first reflecting surface, and a second reflecting surface
Data Source
AI summary
A system for inspecting components is provided. The system includes a prism having a first end, a second end, a first reflecting surface, and a second reflecting surface. The first end of the prism is located in a plane that is parallel to and axially separated from a plane of one or more of a plurality of inspection pieces. An image data system is disposed beyond the second end of the prism and generates image data of one or more of the inspection piece that includes a top surface of at least one of the inspection pieces and at least one side of at least one of the inspection pieces. An inspection piece transportation system, such as a pick and place tool or conveyor, moves a plurality of inspection pieces past the first end of the prism through an inspection area.