Slice Scan Imaging System for Conveyor Belt Inspection
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Solution Overview
Problem
Conventional image capture systems for postal sorting and defect inspection on conveyor belts face challenges with short exposure times, intense lighting requirements, and distortion due to object movement, which are not effectively addressed by typical frame cameras or line scan cameras.
Innovation Solution
A slice scan imaging system that captures multiple lines of an image in a single slice, stitches together slices by aligning common features, and blends them to form a seamless image, allowing for high-quality image capture without distortion or blur, even at high speeds and low light levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If frame cameras are used to capture large image areas simultaneously, then the image area coverage is improved, but the exposure time increases and intense lighting is required
Solution Approach 1:
The patent divides the image capture process into multiple narrow vertical slices captured sequentially as the object moves along the conveyor belt. Each slice captures a narrow vertical strip of the object, and multiple slices are stitched together to form the complete image. This segmentation allows for short exposure times per slice while covering the entire object area through temporal and spatial division.
2Loss of time
If line scan cameras are used for conveyor imaging, then the exposure time is reduced, but the ability to handle rocking motion and perform advanced image processing is limited
Solution Approach 1:
The patent extends the traditional line scan approach by capturing multiple lines simultaneously in each vertical slice, creating a two-dimensional slice rather than a single line. This dimensional enhancement allows for better handling of rocking motion through multiple reference lines and enables advanced image processing operations such as stitching, blending, and noise reduction that were not possible with conventional line scan cameras.
3Illumination intensity
If TDI camera is used to capture images at lower light levels, then the illumination requirement is reduced, but the image quality degrades if the object moves in directions other than the direction of travel
Solution Approach 1:
The patent employs feedback mechanisms through the stitching and blending process. Multiple overlapping slices are captured with deliberate redundancy, and the system uses feature matching and alignment algorithms to detect and correct for object motion, including rocking motion. The blending process weights and combines information from multiple slices to produce a final image that compensates for motion artifacts, maintaining high quality even when objects move in unintended directions.
4Productivity
If intense lighting is used to capture images at high belt speeds, then the productivity is improved, but the energy consumption and glare increase
Solution Approach 1:
The patent segments the illumination requirement across multiple narrow slices captured sequentially, allowing each slice to use lower intensity lighting compared to illuminating the entire field of view simultaneously. The focused illumination on narrow vertical strips reduces overall energy consumption while maintaining sufficient light levels for high-speed capture. The segmented approach also reduces glare by limiting the illuminated area at any given moment.
Data Source
AI summary
The disclosure is directed to systems and methods for image capturing technologies and, more particularly, to a slice scan imaging system and respective processes to achieve high quality images. The method can be implemented in a computing device, which includes: capturing multiple lines of an image in a single slice; capturing multiple slices; stitching together the multiple slices by aligning common features of the images of a previous slice with a successive slice; and blending together the stitched together multiple slices.