Structured Light Deflectometry for Tempered Glass Fragmentation Inspection
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Solution Overview
Problem
Conventional methods for inspecting the fragmentation patterns of tempered glass panels, such as those used in automotive and architectural applications, are labor-intensive and inefficient, especially when dealing with low light transmission glasses, and require manual processing of images, which can lead to inaccuracies and increased time for data acquisition.
Innovation Solution
A method utilizing a structured light pattern projected onto the tempered glass panel, captured by an image device, and processed using deflectometry principles to obtain high-resolution images of fragmentation patterns, allowing for automated analysis and reducing reliance on light transmission characteristics, thereby improving accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional optical inspection methods are used to determine fragmentation patterns, then the inspection can be performed, but the process requires considerable manual labor and time for counting fragments and measuring dimensions
Solution Approach 1:
The patent replaces manual mechanical counting and measurement operations with an automated optical inspection system. The system uses a camera to capture images of fragmentation patterns and automatically processes these images to count fragments and measure their dimensions, eliminating the need for manual labor while significantly improving inspection speed and consistency.
Solution Approach 2:
The patent creates a digital copy of the fragmentation pattern by capturing an image of the fragmented glass surface. This digital image serves as a copy that can be analyzed by computer algorithms to determine fragment count, size distribution, and pattern characteristics, replacing the need for direct manual measurement of physical fragments.
2Measurement precision
If a screen is used to project the image of fragments for camera detection, then the image can be captured, but the method increases data acquisition time especially for low light transmission glass
Solution Approach 1:
The patent introduces a screen as an intermediary surface to project the fragmentation pattern image. The screen diffuses and redistributes light from the fragmented glass, creating a visible image that can be captured by the camera. This intermediary approach enables image capture of low light transmission glass while maintaining reasonable acquisition times through optimized lighting and screen properties.
Solution Approach 2:
The patent modifies lighting parameters and screen properties to optimize the balance between image quality and acquisition time. By adjusting light source intensity, spectral characteristics, and screen material properties, the system achieves sufficient image contrast for accurate measurement without requiring excessive exposure times that would slow down the inspection process.
3Reliability
If photosensitive paper is used to obtain blueprinted images for fragment analysis, then the fragmentation pattern can be recorded, but the process requires manual operations and considerable labor
Solution Approach 1:
The patent replaces the chemical photosensitive paper process with a digital imaging system. Instead of using photosensitive paper that requires manual handling, development, and interpretation, the system uses a camera to capture digital images that can be immediately processed by computer algorithms, achieving both high reliability in pattern recording and full automation of the analysis process.
Solution Approach 2:
The patent creates a digital copy of the fragmentation pattern through camera imaging, replacing the physical blueprint on photosensitive paper. This digital copy can be stored, transmitted, and analyzed automatically without manual intervention, eliminating the labor-intensive steps of paper handling while preserving the accuracy of the fragmentation pattern recording.
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 enables rapid and precise analysis of fragmentation patterns on both high and low light transmission glasses, reducing labor costs and time, while providing clear, reproducible results that meet safety standards like ECE R43 and EN12150, and allows for better understanding of the fragmentation patterns and adaptation of tempering conditions.
Implementation Method 1
capturing an image reflected by the surface of the first portion of the tempered glass panel using an image capture device
Data Source
AI summary
A method and installation of inspecting a fragmentation pattern of a tempered glass panel by deflectometry, following a fragmentation test, the method including: (i) positioning the tempered glass panel in contact with a support; (ii) projecting by a display device a structured light pattern on the surface of at least one portion of the tempered glass panel; (iii) capturing an image reflected by the surface of the first portion of the tempered glass panel using an image capture device; and (vi) processing the images to determine the fragmentation pattern by an image processing device.