Rotatable Illumination Units for Automated Optical Inspection
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Solution Overview
Problem
Existing automated optical inspection systems are product-oriented and lack flexibility in illumination angles, requiring multiple inspection stations and increasing costs, with limited ability to adjust illumination independently to match camera viewing angles.
Innovation Solution
An apparatus with rotatable illumination units, each comprising LEDs, driven by a motorized gear system that allows synchronized adjustment of illumination angles from 0 to 90 degrees, integrated with a digital camera and varifocal lens for enhanced visualization, and adaptable for mounting on a multi-axis robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple inspection stations are used to achieve full inspection coverage, then inspection completeness is improved, but system cost and complexity increase
Solution Approach 1:
The patent implements a motorized rotation mechanism that allows the illumination units to dynamically adjust their angles independently. This dynamic adjustment capability enables a single inspection station to achieve multiple inspection configurations, replacing the need for multiple fixed inspection stations and thereby reducing system complexity while maintaining comprehensive inspection coverage.
Solution Approach 2:
The inspection apparatus is designed with multi-functional illumination units that can be positioned at various angles to inspect different defect types. This universal design allows one inspection station to perform the functions previously requiring multiple specialized stations, achieving full inspection coverage without increasing the number of stations.
2Adaptability or versatility
If fixed illumination angles are used in inspection systems, then system simplicity is maintained, but inspection flexibility and defect visualization capability are limited
Solution Approach 1:
The illumination units are equipped with motorized rotation mechanisms that enable dynamic angle adjustment. This allows the system to adapt illumination angles to match different camera viewing angles and inspect various defect types, transforming a static illumination system into a dynamic one that can be configured for different inspection scenarios without requiring multiple fixed systems.
Solution Approach 2:
The illumination system is divided into multiple independent illumination units, each capable of independent rotation and angle adjustment. This segmentation allows each unit to be optimized for specific inspection tasks while maintaining overall system simplicity, as each unit operates independently rather than requiring complex coordinated control of a unified illumination system.
3Adaptability or versatility
If multiple layers or angles of lighting with various colours are integrated, then inspection coverage is maximized, but system complexity and cost increase
Solution Approach 1:
Instead of integrating multiple fixed lighting layers, the patent uses dynamically adjustable illumination units that can be rotated to different angles. This dynamic approach achieves multiple lighting angles from a single set of illumination units, reducing the need for multiple integrated lighting layers and simplifying the overall lighting system configuration while maintaining comprehensive inspection coverage.
Solution Approach 2:
The illumination units can change their operational parameters including angle of incidence and colour temperature to suit different inspection requirements. This parameter variability allows a single illumination unit to replace multiple fixed lighting configurations, achieving diverse inspection coverage without the complexity of integrating multiple lighting systems with different colours and angles.
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 flexible and comprehensive inspection coverage by allowing independent adjustment of illumination angles, improving defect visualization and reducing the need for multiple inspection stations, thereby enhancing inspection efficiency and cost-effectiveness.
Implementation Method 1
Each illumination unit may include a bar light comprising a plurality of LEDs
Data Source
AI summary
An apparatus for use in an automated optical inspection in a production line, the apparatus including a frame accommodating a plurality of illumination units surrounding an integrated optical imaging unit, wherein each illumination unit is rotatable in a synchronized manner relative to each unit, in use, to vary an illumination angle at an intended target, to enhance the visualization of the intended target captured by the optical imaging unit.