Reflective Dome Illumination for Inspection Systems
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Solution Overview
Problem
Camera-based inspection systems face challenges in providing both on-axis and diffuse illumination effectively, as existing combinations often generate excessive heat and do not accommodate conventional configurations, leading to light loss and blind spots.
Innovation Solution
The system incorporates a reflective dome with a viewport offset from its apex, surrounded by a plurality of light sources, including LEDs, which directs light to illuminate parts both diffusely and orthogonally, eliminating the need for a beam splitter and minimizing heat generation through a heat sink and coolant system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional beam splitter configuration is used to provide on-axis illumination, then illumination intensity is improved, but device complexity and light loss increase
Solution Approach 1:
The patent removes the beam splitter from the optical path entirely, extracting this complex component while maintaining on-axis illumination capability through a different approach - using a reflective dome with light sources positioned around it to illuminate parts orthogonally to the camera axis.
Solution Approach 2:
Instead of using a beam splitter to divide light paths, the patent inverts the approach by using a reflective dome to redirect light from surrounding sources into an on-axis configuration, achieving the same illumination effect through opposite means.
2Illumination intensity
If multiple light sources are added to provide diffuse illumination, then illumination uniformity is improved, but heat generation increases
Solution Approach 1:
The patent employs a dome-shaped reflective structure that naturally distributes light from multiple sources in a diffuse manner, achieving uniform illumination without requiring excessive light intensity from each individual source, thereby reducing heat generation.
Solution Approach 2:
The reflective dome acts as an intermediary between the light sources and the inspected part, diffusing and redistributing the light to achieve uniform illumination while allowing the use of lower-power LED sources that generate less heat.
3Illumination intensity
If on-axis illumination is used, then shadow reduction is improved, but blind spots are created
Solution Approach 1:
The patent applies different illumination characteristics to different regions of the inspection field by positioning light sources around the dome perimeter, with each source contributing to specific areas, thereby achieving both shadow reduction and complete coverage without blind spots.
Solution Approach 2:
The patent transitions from a single-point on-axis light source to a distributed array of light sources positioned in multiple dimensions around the dome, adding spatial distribution as a new dimension to achieve comprehensive illumination coverage.
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 configuration provides enhanced illumination that combines the benefits of on-axis and diffuse lighting, reducing shadows and heat while maintaining high fluence, allowing for accurate inspection of small parts without blind spots.
Implementation Method 1
The housing contains a reflective dome. The plurality of light sources are arranged about the reflective dome such that light output from the plurality of light sources enters the dome
Implementation Method 2
minimizing heat generation through a heat sink and coolant system
Implementation Method 3
coolant system
Data Source
AI summary
An inspection system is described. The inspection system includes a camera and a housing. The housing contains a reflective dome. The reflective dome includes an apex and a viewport. The viewport is offset from the apex. The camera is mounted to capture light exiting the reflective dome through the viewport. And, a plurality of light sources are arranged about the reflective dome such that light output from the plurality of light sources enters the dome.