Sequential Image Stitching for High-Resolution Conveyor Surface Imaging
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Solution Overview
Problem
Existing imaging systems struggle to capture high-resolution images of the bottom side of objects moving on a conveyor due to physical constraints, leading to partial views and increased computational costs with line-scan cameras, while area scan sensors face challenges in capturing complete images of varying object geometries.
Innovation Solution
A system using a transport device with a viewing area, 2D digital optical sensors, and a controller that captures sequential images and stitches them together using a stitching algorithm, incorporating a light source and motion encoder for precise image alignment and illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If line-scan cameras are used to image objects on conveyor, then cost is reduced and wide field of view is achieved, but computational processing requirements increase significantly and system cost increases
Solution Approach 1:
The patent divides the imaging task into multiple segments by using multiple area scan cameras positioned at different locations (e.g., front, rear, left, right) to capture partial views of objects. These segmented images are then stitched together computationally, distributing the processing load across multiple simpler camera units rather than requiring a single complex line-scan system.
Solution Approach 2:
The patent uses multiple area scan cameras as copies of the same basic imaging unit, each capturing a different portion of the object's surface. This approach replaces the need for expensive line-scan cameras with multiple simpler, more affordable area scan cameras that can be easily positioned and configured.
2Ease of operation
If area scan image sensors are used, then setup and alignment are easier and flexibility is greater, but only partial views of objects may be captured requiring reconstruction processing
Solution Approach 1:
The patent merges multiple partial views captured by different area scan cameras into a complete image representation. By combining the information from front, rear, left, and right camera positions, the system reconstructs the full object geometry, overcoming the limitation of any single camera capturing only a partial view.
Solution Approach 2:
The patent transitions from single-view imaging to multi-view imaging by adding spatial dimensionality. Instead of using one camera that must capture the entire object from multiple angles (which is difficult), the system uses multiple cameras positioned at different spatial locations, each capturing a convenient partial view that can be easily stitched together.
3Measurement precision
If multiple cameras are used to image each side of an object, then adequate resolution and coverage are achieved, but system complexity increases
Solution Approach 1:
The patent designs the camera system with multi-functionality in mind, where each area scan camera is capable of capturing images from its specific viewpoint and the same camera type can be used for multiple positions (front, rear, left, right). This standardized approach reduces overall system complexity compared to using different specialized cameras for each function.
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 high-resolution imaging of objects' surfaces by stitching partial views into complete images, improving efficiency and reducing computational costs by utilizing area scan sensors effectively.
Implementation Method 1
at least one 2D digital optical sensor configured to capture at least two sequential 2D digital images of the at least one substantially planar surface of the at least one object
Implementation Method 2
a light source configured to illuminate the at least one object in the viewing area
Data Source
AI summary
A system may comprise a transport device for moving at least one object, wherein at least one substantially planar surface of the object is moved in a known plane locally around a viewing area, wherein the substantially planar surface of the object is occluded except when the at least one substantially planar surface passes by the viewing area, at least one 2D digital optical sensor configured to capture at least two sequential 2D digital images of the at least one substantially planar surface of the at least one object that is moved in the known plane around the viewing area, and a controller operatively coupled to the 2D digital optical sensor, the controller performing the steps of: a) receiving a first digital image, b) receiving a second digital image, and c) stitching the first digital image and the second digital image using a stitching algorithm to generate a stitched image.