Shadow Calibration Reference for Lighting Setup Verification
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Solution Overview
Problem
Automated inspection systems face challenges in verifying the location of imaging devices and light sources for dark field illumination, particularly in enhancing the visibility of micro defects on non-Lambertian materials and maintaining illumination quality during relocation, which affects the accuracy and efficiency of defect detection.
Innovation Solution
A method involving the generation of a simulated setup to optimize the positioning of imaging devices and light sources, creating a shadow calibration reference that is then validated by comparing simulated and physical shadow parameters, allowing for the verification of the lighting setup without the need for recalibration during relocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the imaging device and light source are relocated to inspect different areas or reconfigure the inspection system, then the adaptability of the system is improved, but the illumination quality and shadow parameters change, requiring time-consuming recalibration
Solution Approach 1:
The patent applies preliminary action by creating a simulated setup before physical relocation. The system generates a shadow calibration reference rendering in advance that predicts the shadow parameters for the intended physical configuration. This allows the imaging device and light source to be relocated without requiring time-consuming recalibration, as the expected shadow characteristics are already known from the simulation.
Solution Approach 2:
The patent uses a simulated shadow calibration reference as a copy or representation of the physical shadow calibration reference. The simulated rendering replicates the shadow parameters that would result from the physical setup, allowing verification of illumination quality without physically recalibrating the system after relocation.
2Measurement precision
If the imaging device and light source positions are adjusted to optimize viewing of micro defects, then the detection precision is improved, but the complexity of setup verification increases
Solution Approach 1:
The patent creates a simulated shadow calibration reference rendering that copies the expected shadow parameters for the optimized setup. This simulation acts as a virtual template that can be compared against actual measurements, simplifying the verification process while maintaining high detection precision for micro defects.
Solution Approach 2:
The system uses feedback by comparing the simulated shadow calibration reference with actual measurements from the physical setup. This feedback loop verifies whether the optimized positions of the imaging device and light source produce the expected shadow parameters, ensuring high detection precision while providing a straightforward verification process.
3Reliability
If a physical shadow calibration reference is used to verify illumination quality, then the reliability of inspection is improved, but the time required for calibration and verification increases
Solution Approach 1:
The patent replaces the physical shadow calibration reference with a simulated shadow calibration reference rendering. This virtual copy contains the expected shadow parameters and can be instantly generated without requiring physical calibration objects or time-consuming measurement processes, while still ensuring inspection accuracy through comparison with actual setup results.
Solution Approach 2:
The simulated shadow calibration reference is generated in advance before the actual inspection or verification process. This preliminary generation of expected shadow parameters eliminates the need for time-consuming physical calibration and verification steps, while maintaining the reliability of inspection through systematic comparison of simulated and actual shadow characteristics.
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 method ensures accurate and efficient detection of micro defects by optimizing illumination geometry and camera placement, enhancing the visibility of small surface discontinuities and simplifying the relocation process for inspection systems, thereby improving the performance of machine vision applications.
Implementation Method 1
The light source 18 generates sufficient light to illuminate a first portion 22 of the defect 12 to form a bright region 24 whereas a second portion 26 of the defect 12 is not illuminated to form a dark or shadow region 28
Data Source
AI summary
A method for verifying a lighting setup used for inspecting a micro defect. The method includes simulating a scene including a micro defect, light source and imaging device. A position of the light source and imaging device is then optimized to form an optimized simulated setup for viewing micro defect. A shadow calibration reference (SCR) having a simulated shadow field is then rendered in a location. Next, a physical imaging device and light source are positioned based on information from the optimized simulated setup to form an optimized physical setup. A physical SCR based on information from the SCR rendering is fabricated. Next, an image is captured of a physical SCR in a corresponding location associated with each SCR rendering. The optimized physical setup is verified if at least one shadow parameter from the SCR rendering is substantially similar to a corresponding shadow parameter in a corresponding image.