Robotic Camera Calibration for Multi-Surface Defect Inspection
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Solution Overview
Problem
Existing defect inspection systems require manual adjustment of camera angles and illumination settings for each type of industrially made article, making it inefficient and prone to errors.
Innovation Solution
An automatic target image acquisition and calibration system that uses a first robotic arm and camera to acquire 2D images, determine the relative position and 3D coordinate of the article, and then control a second robotic arm and camera to automatically adjust the camera positions and acquire images from multiple surfaces of the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of camera angles and illumination settings is used for each type of article, then the inspection system can be adapted to different products, but the process becomes inefficient and prone to errors
Solution Approach 1:
The system automatically acquires target images and calculates camera parameters without manual intervention. The electronic device autonomously controls the robotic arm to position the camera, captures images at different angles, and computes the calibration parameters, enabling the system to serve itself in the adaptation process.
Solution Approach 2:
The system performs automatic target image acquisition and parameter calculation before the actual inspection process. By pre-acquiring images from multiple angles and pre-calculating camera parameters, the system prepares all necessary data in advance, eliminating the need for manual adjustment during product changeovers.
2Measurement precision
If manual adjustment of camera positions is performed, then the system can be configured for specific products, but the process is time-consuming and requires skilled engineers
Solution Approach 1:
The system replaces manual mechanical adjustment of camera positions with an automated robotic arm controlled by an electronic device. The robotic arm precisely positions the camera based on automatically calculated parameters, substituting human mechanical operations with automated mechanical control driven by image processing algorithms.
Solution Approach 2:
The system automatically calculates and adjusts camera parameters including position, angle, and illumination settings based on the target object's characteristics. By dynamically changing these parameters through automatic computation rather than manual setting, the system achieves precise positioning rapidly without requiring engineer expertise.
3Reliability
If multiple cameras are used to inspect all surfaces of an article, then inspection coverage is improved, but the system complexity increases
Solution Approach 1:
Instead of using multiple fixed cameras simultaneously, the system employs a single camera mounted on a robotic arm that dynamically changes position and orientation. The camera moves to different locations around the article, capturing images from multiple angles sequentially, thereby achieving comprehensive coverage with a single movable camera rather than multiple static cameras.
Solution Approach 2:
The system adds the dimension of time and motion to the inspection process. Rather than arranging multiple cameras in space to cover all surfaces simultaneously, the single camera traverses through three-dimensional space around the article, capturing images from different spatial positions and angles over time, effectively using spatial-temporal dimensionality to achieve complete coverage.
Data Source
AI summary
An automatic target image acquisition and calibration system for application in a defect inspection system is disclosed. During the defect inspection system working normally, the automatic target image acquisition and calibration system is configured to find a recognition structure from an article under inspection, and then determines a relative position and a relative 3D coordinate if the article. Therefore, a robotic arm is controlled to carry a camera to precisely face each of a plurality of inspected surfaces of the article, such that a plurality of article images are acquired by the camera. It is worth explaining that, during the defect inspection of the article, there is no need to modulate an image acquiring height and an image acquiring angle of the camera and an illumination of a light source.