Surface Inspection Camera With Multi-Angle Lighting
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Solution Overview
Problem
Conventional surface inspection methods for painted workpieces, such as car bumpers, rely heavily on human observation, which is prone to missed defects and inconsistent quality judgments, leading to unnecessary rework and potential customer complaints, while existing automated systems struggle with distinguishing defects from surface shading and require multiple perspective views, increasing examination time.
Innovation Solution
A surface inspection apparatus with a camera and two light sources mounted on an actuator, where the optical axes of the light sources intersect at a non-zero angle, allowing for rapid and reliable defect detection by comparing images taken under different lighting conditions without changing camera perspective, using LEDs for alternating illumination and a controller to analyze defects based on brightness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple perspective views are used to inspect the surface, then defect detection reliability is improved, but examination time increases greatly
Solution Approach 1:
The patent transitions from temporal dimension (multiple views over time) to spatial dimension (multiple light angles simultaneously). By arranging light sources at different angles around the camera, the system captures multi-angle illumination effects in a single snapshot, achieving comprehensive defect detection without sequential perspective changes.
Solution Approach 2:
The patent pre-arranges multiple light sources at specific angles around the camera before inspection begins. This preliminary spatial configuration allows the system to capture all necessary lighting conditions simultaneously, eliminating the need for time-consuming sequential perspective changes while maintaining comprehensive defect detection capability.
2Difficulty of detecting and measuring
If the robot arm moves to illuminate the surface from different directions, then defect detection capability is improved, but the perspective of the camera varies making evaluation difficult
Solution Approach 1:
The patent merges the lighting function and camera positioning into a single stationary assembly. Multiple light sources are integrated around the camera, allowing simultaneous multi-angle illumination while maintaining fixed camera perspective. This combination eliminates the perspective variation problem that occurs when separate lighting and imaging systems move independently.
Solution Approach 2:
The patent introduces a stationary camera as an intermediary that remains fixed while multiple light sources provide varied illumination angles. This fixed camera acts as a stable reference point, capturing consistent perspective images illuminated from different directions, thereby maintaining perspective consistency while improving defect detection capability.
3Reliability
If every workpiece with a detected defect is touched up, then customer complaint prevention is improved, but unnecessary rework costs increase
Solution Approach 1:
The patent replaces subjective human visual inspection with an automated optical inspection system using multiple light sources and image processing. This objective mechanical/optical system provides consistent, measurable defect detection criteria, enabling precise differentiation between acceptable and unacceptable defects, thereby reducing unnecessary rework while maintaining customer satisfaction.
Solution Approach 2:
The patent changes the inspection parameters from subjective human judgment to objective optical measurement parameters. By using multiple light angles and quantitative image analysis, the system establishes precise defect thresholds and criteria, allowing accurate classification of defects and determination of which workpieces require rework, thus minimizing unnecessary costs while preventing complaints.
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 quick and accurate detection of defects, reducing unnecessary rework by ensuring only critical defects are addressed, while minimizing examination time and avoiding customer complaints.
Implementation Method 1
a first light source mounted to the actuator apparatus for joint displacement with the camera; wherein the apparatus further comprises a second light source arranged so that an angle in which optical axes of the first and second light sources intersect is non-zero
Data Source
AI summary
A surface inspection apparatus comprises a camera, an actuator apparatus for displacing the camera relative to a surface to be inspected; a first light source mounted to the actuator apparatus for joint displacement with the camera; and a second light source arranged so that an angle in which optical axes of the first and second light sources intersect is non-zero.