Single-Camera Multi-Mirror Imaging for Rotating Object Inspection
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Solution Overview
Problem
Current methods for inspecting spherical objects, such as fruits and vegetables, are slow and unreliable due to human visual inspection and require complex, expensive machine vision systems with multiple cameras to detect defects and contaminants on moving production lines, which are difficult to synchronize and process effectively.
Innovation Solution
A single-camera imaging system using a central collecting mirror and peripheral mirrors positioned around a rotating object to gather and process reflected images, creating a two-dimensional image cube for defect and contamination identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple cameras are used to inspect all surfaces of a spheroid, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The inspection system divides the imaging task into multiple segments by using multiple mirrors (first mirror, second mirror, third mirror) positioned at different locations around the spheroid. Each mirror captures images of different portions of the rotating spheroid, allowing complete surface inspection to be achieved through segmented imaging rather than requiring multiple cameras to simultaneously capture all views.
Solution Approach 2:
The system introduces a rotating platform as an intermediary element between the stationary single camera and the spheroid being inspected. The spheroid rotates on this platform, bringing different surfaces into view of the camera sequentially. This intermediary mechanism enables a single camera to capture images of all surfaces over time, eliminating the need for multiple cameras while maintaining complete inspection coverage.
2Measurement precision
If multiple cameras are used to capture images of all surfaces, then measurement precision is improved, but loss of time increases due to data synchronization requirements
Solution Approach 1:
The imaging process is segmented into sequential captures by different mirrors during a single rotation cycle. Instead of synchronizing data from multiple cameras simultaneously, the system captures images from different portions of the spheroid in sequence as it rotates, with each mirror capturing its portion independently. This segmentation of the imaging process eliminates the complex real-time synchronization requirements while maintaining complete surface coverage.
Solution Approach 2:
The spheroid is rotated in advance through a complete 360-degree cycle, which preliminarily positions all surfaces sequentially in front of the stationary camera and mirrors. This preliminary rotation action ensures that by the time image processing occurs, all necessary image data has already been captured in the correct temporal sequence, eliminating the need for complex post-capture synchronization of multiple camera streams.
3Ease of operation
If human visual inspection is used, then ease of operation is maintained, but productivity decreases due to slow inspection speed
Solution Approach 1:
The system enables self-service inspection by automatically capturing, processing, and analyzing images of the spheroid as it rotates on the platform. The computer automatically receives images from the camera, processes them to identify defects and contaminants, and determines whether the spheroid meets quality standards. This eliminates the need for human inspectors to manually examine each spheroid while maintaining operational simplicity through automated decision-making.
Solution Approach 2:
The patent replaces the mechanical human visual inspection process with an automated optical-mechanical system. Instead of human eyes and brain processing images manually, the system uses a camera to capture images, a computer to process and analyze them, and automated algorithms to identify defects. This substitution dramatically increases inspection speed while keeping the system easy to operate through automated control.
4Reliability
If machine vision systems with multiple cameras are implemented, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The inspection function is segmented across multiple mirrors rather than requiring multiple cameras. Each mirror is positioned to capture images of specific portions of the rotating spheroid, and the computer integrates these segmented views into a complete inspection assessment. This segmentation approach achieves reliable multi-angle inspection using a single camera system, reducing complexity while maintaining reliability.
Solution Approach 2:
The single camera system is made universal by combining it with multiple mirrors and a rotating platform. The camera itself remains stationary and performs a single function (capturing images), but the combination of the rotating spheroid, multiple mirrors, and computer processing creates a multi-functional inspection system that can view all surfaces from multiple angles. This universal approach achieves the reliability of multi-camera systems while using simpler, fewer components.
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
Simplifies the inspection process by enabling efficient data collection and processing, allowing for accurate identification of surface defects and contaminants with reduced equipment costs and improved reliability.
Implementation Method 1
peripheral image collecting mirrors positioned around a targeted rotating object. The peripheral mirrors direct reflected images of the object to a central collecting mirror.
Data Source
AI summary
The single-camera multi-mirror imaging method and apparatus is an inspection system configured to examine a whole surface of a rotating object, preferably a spheroidal object such as a fruit or vegetable. The system includes a plurality of mirrors that direct an image of the inspected object into a digital line scan camera with an associated processor. The processor produces an image of the inspected object showing any detected surface defects and selected contamination on the outer surface of the object.