Surface Inspection System Using Segmented Illumination
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Solution Overview
Problem
Current surface inspection systems face challenges in efficiently detecting surface defects on optically lustrous surfaces due to their large size, weight, and the need for extensive illumination areas, which limits their applicability in industrial manufacturing, particularly in automated robotic applications where they struggle to keep up with manufacturing cycles and differentiate defects from changes in scattering and reflection properties.
Innovation Solution
A surface inspection system utilizing multiple cameras and spatially separate light sources or regions of different colors, allowing for the evaluation of brightness and color distributions to identify surface defects as local deviations, which appear brighter in one region and darker in another, or with dominant different colors, enabling reliable detection on optically rough and lustrous surfaces without requiring extensive illumination areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional surface inspection systems use large illumination areas and extensive equipment, then detection capability is improved, but system size and weight increase
Solution Approach 1:
The patent divides the illumination system into multiple spatially separate light sources and the detection system into multiple cameras, each capturing specific regions. This segmentation allows the system to achieve comprehensive surface inspection coverage without requiring a single large, heavy illumination area, thereby reducing overall system weight while maintaining detection precision.
Solution Approach 2:
The patent transitions from a single-plane illumination approach to a multi-dimensional arrangement where light sources are positioned at different spatial locations and angles relative to the surface. This dimensional change enables defect detection through multiple viewing angles and illumination conditions without requiring a large footprint, reducing system size and weight.
2Measurement precision
If conventional surface inspection systems use extensive illumination areas, then detection capability is improved, but device complexity increases
Solution Approach 1:
The illumination system is segmented into multiple independent light sources positioned at different locations, each illuminating specific surface regions from different angles. This segmentation simplifies the control of each individual light source while achieving comprehensive illumination coverage, reducing overall system complexity.
Solution Approach 2:
The multiple light sources and cameras are designed to serve multiple functions: they provide both illumination and detection capabilities, can inspect different surface regions simultaneously, and can differentiate between defects and scattering property changes through comparative analysis. This multi-functionality reduces the need for separate specialized components, simplifying the overall device.
3Measurement precision
If conventional surface inspection systems are designed for stationary inspection, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The patent pre-arranges multiple light sources and cameras in fixed spatial relationships before inspection begins. This preliminary configuration allows the system to capture multiple surface regions simultaneously from different angles, enabling high-speed inspection without sacrificing measurement precision that would result from sequential scanning.
Solution Approach 2:
The multiple cameras and light sources operate simultaneously and continuously to capture surface defects across different regions and angles at the same time. This continuous parallel operation eliminates idle time between measurements, maintaining high productivity while ensuring comprehensive and precise defect detection through multiple viewing conditions.
4Device complexity
If conventional surface inspection systems use single-color illumination, then device complexity is reduced, but ability to differentiate defects from scattering changes decreases
Solution Approach 1:
The patent applies different colors or wavelengths of illumination to different spatial regions or uses multiple light sources emitting different colors simultaneously. This local quality differentiation allows the system to capture how surface defects and scattering property changes respond differently to various wavelengths, enabling precise differentiation without requiring complex spectral analysis equipment.
Solution Approach 2:
The system utilizes color variations in the illumination light sources to create contrast between defects and scattering property changes. Different materials and surface conditions reflect and absorb different colors differently, allowing the inspection system to differentiate defects from scattering changes by analyzing color distribution patterns across the illuminated surface.
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 approach reduces the size and weight of the inspection system, allowing for faster and more precise surface inspection with simultaneous image recording, enabling the detection of surface defects during relative movement between the system and the object, and improving handling and measurement speed in automated applications.
Implementation Method 1
the illumination system generates, together with the reflection and scattering properties of the surface to be checked, a brightness distribution in which surface defects become visible
Implementation Method 2
the illumination system generates, together with the reflection and scattering properties of the surface to be checked, a brightness distribution in which surface defects become visible
Data Source
AI summary
A surface inspection system for capturing surface defects of a surface to be checked, includes a camera system, an illumination system including one or more light sources, and an evaluation system. The evaluation system evaluates a brightness and/or color distribution of the surface to be checked in at least one image captured by the camera system and captures surface defects of the surface to be checked as local deviations in the brightness and/or color. The evaluation system is configured to assess a local deviation in the brightness and/or color as a surface defect when the local deviation appears brighter in at least one first subregion and darker in at least one second subregion than a surface region surrounding the local deviation, and/or different colors are dominant in different subregions.