Telecentric Lens Array for 360-Degree Part Inspection
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Solution Overview
Problem
Current automatic inspection methods for small arms ammunition cartridges and threaded fasteners are inadequate in detecting defects such as splits, dents, and surface blemishes, as they often require part rotation and are not capable of high-speed, 360-degree inspections.
Innovation Solution
A method and system for optically inspecting parts using a telecentric lens and detector assembly that illuminates multiple exterior side surfaces with separate beams of radiation, forming optical images and processing them to identify defects like dents, splits, and surface blemishes without part rotation, enabling high-speed 360-degree inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional automatic inspection methods are used, then inspection speed can be maintained, but defect detection accuracy deteriorates due to inability to detect splits, dents, and surface blemishes
Solution Approach 1:
The inspection system segments the inspection task by using multiple detectors arranged at different angular positions around the part's axis. Each detector captures images of specific surfaces, and the system processes these segmented views separately before combining them into a complete 360-degree inspection result. This segmentation enables high-speed parallel processing while maintaining comprehensive defect detection coverage.
Solution Approach 2:
The system transitions from traditional single-view inspection to multi-angular 3D inspection by arranging detectors in a circular array around the part's axis. This dimensional change from 2D planar inspection to 360-degree volumetric inspection enables detection of defects on all surfaces simultaneously without requiring part rotation, thereby maintaining high inspection speed while improving detection accuracy.
2Reliability
If part rotation is used to achieve 360-degree inspection, then comprehensive defect detection is improved, but inspection speed deteriorates due to mechanical rotation requirements
Solution Approach 1:
Instead of rotating the part to achieve 360-degree inspection, the system inverts the approach by keeping the part stationary and rotating the detectors around the part's axis. This inversion eliminates mechanical rotation of the part itself, enabling high-speed electronic scanning while maintaining comprehensive defect detection coverage across all surfaces.
Solution Approach 2:
The system replaces mechanical part rotation with an electronic scanning system where detectors are positioned in a circular array and electronically scanned around the part's axis. This substitution of mechanical rotation with electronic scanning eliminates the speed limitations and mechanical complexity associated with rotating the part, thereby maintaining high inspection speed while achieving comprehensive 360-degree defect detection.
3Reliability
If multiple detectors are used to inspect multiple surfaces simultaneously, then inspection completeness is improved, but system complexity increases
Solution Approach 1:
The system uses a universal detector design where each detector in the circular array is identical and can inspect any surface position when appropriately positioned. This multi-functionality is achieved by arranging identical detectors in a circular array around the part's axis, allowing the same detector type to inspect different surfaces by simply changing its angular position, thereby reducing overall system complexity through component standardization.
Solution Approach 2:
The system merges the inspection function into a single integrated circular array structure where multiple detectors are combined in a compact radial arrangement around the part's axis. This merging of multiple inspection functions into one unified circular configuration enables simultaneous multi-surface inspection while reducing the overall spatial footprint and simplifying system integration compared to distributed inspection systems.
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 efficient detection of defects on ammunition cartridges and threaded fasteners with high-speed, 360-degree inspection capabilities, improving the accuracy and reliability of defect identification in the manufacturing process.
Implementation Method 1
forming an optical image of at least a portion of each of the illuminated side surfaces
Implementation Method 2
illuminating a plurality of exterior side surfaces of the part which are angularly spaced apart about the axis of the part with a plurality of separate beams of radiation
Data Source
AI summary
A method and system for optically inspecting parts are provided wherein the system includes a part transfer subsystem including a transfer mechanism adapted to receive and support a part at a loading station and to transfer the supported part by a split belt conveyor so that the part travels along a first path which extends from the loading station to an inspection station at which the part has a predetermined position and orientation for inspection. An illumination assembly simultaneously illuminates a plurality of exterior side surfaces of the part with a plurality of separate beams of radiation. A telecentric lens and detector assembly forms an optical image of at least a portion of each of the illuminated side surfaces of the part and detects the optical images. A processor processes the detected optical images to obtain a plurality of views of the part which are angularly spaced about the part.In an alternative embodiment the method and system for optically inspecting headed manufactured parts employ an inclined split track to cause the part to traverse an inspection station by gravity feed. The part is inspected for conformity to dimensional and visual standards and sorted under control of a processor based on images of the part obtained from occluded light and reflected light while the part is within the inspection station.