Projection Chamber Residue Detection via Image Comparison
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Solution Overview
Problem
Existing workpiece processing systems, such as those described in Japanese Unexamined Patent Publication No. 2011-110642, cannot confirm the complete discharge of workpieces after treatment, leading to potential residue issues that affect product quality and efficiency.
Innovation Solution
A workpiece processing apparatus comprising a cabinet with a projection chamber, a projector, an image sensor, and a control unit that captures initial and inspection images to determine the presence or absence of residue, ensuring complete discharge confirmation by comparing these images and outputting relevant information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the rotary drum tilts to discharge workpieces, then the discharge function is improved, but the ability to confirm complete discharge deteriorates
Solution Approach 1:
The patent uses image sensors to create visual copies (images) of the projection chamber interior. These images serve as information records that allow operators to confirm discharge completeness without physically inspecting the chamber, thus resolving the contradiction between easy discharge operation and discharge confirmation capability.
Solution Approach 2:
The patent introduces image sensors and control units as intermediaries between the discharge mechanism and the operator. These intermediaries capture and transmit information about the chamber interior, enabling confirmation of discharge completeness without requiring direct observation or complex mechanical indicators.
2Loss of information
If image sensors are added to capture chamber images, then discharge confirmation is improved, but device complexity increases
Solution Approach 1:
The image sensors and control units serve multiple functions: capturing chamber images, determining workpiece presence/absence, and providing discharge confirmation. This multi-functionality reduces the need for separate dedicated components, thereby mitigating the increase in device complexity while improving discharge confirmation capability.
3Loss of information
If manual inspection of the projection chamber is performed, then discharge confirmation is improved, but productivity decreases
Solution Approach 1:
The system performs automatic discharge confirmation through image sensors and automated image processing. The apparatus serves itself by autonomously determining whether workpieces remain in the chamber, eliminating the need for manual inspection and thereby maintaining high productivity while ensuring accurate discharge confirmation.
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated optical system using image sensors and digital image processing. This substitution eliminates the time-consuming manual inspection step while providing more consistent and reliable discharge confirmation, thus improving both productivity and accuracy.
Data Source
AI summary
A workpiece processing apparatus includes: a cabinet having a projection chamber, workpieces being subjected to processing in the projection chamber; a projector configured to project projection media toward the workpieces charged into the projection chamber; an image sensor configured to image the projection chamber to form an image; and a control unit configured to output information relating to presence or absence of a residue in the projection chamber based on an initial image and an inspection image, the initial image being an image formed by the image sensor and being an image of the projection chamber with no workpiece remaining, the inspection image being an image formed by the image sensor and being an image of the projection chamber after discharging processing in which the plurality of workpieces are discharged from the projection chamber.