Vial Liquid Detection via Pattern Refraction
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Solution Overview
Problem
Conventional machine vision systems face challenges in accurately differentiating vials containing clear or small amounts of liquid from empty vials, as mere backlighting does not provide sufficient information for differentiation.
Innovation Solution
A machine vision system with an imager and an illumination source positioned oppositely, using a predetermined pattern like a grid between the illumination source and the vial to capture optical images and detect distortions caused by light refraction through the liquid, employing a processor to analyze these distortions using techniques such as fast Fourier transforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mere backlighting is used to illuminate the vials, then the system is simple and easy to implement, but the system cannot provide sufficient information to differentiate vials containing clear liquid from empty vials
Solution Approach 1:
A predetermined pattern (intermediary element) is introduced between the illumination source and the vial. This pattern serves as a mediator that interacts with the liquid to produce detectable optical effects. The pattern is illuminated by the backlighting source, and when liquid is present in the vial, it refracts the light from the pattern, creating visible distortions that can be captured by the imager and analyzed by the processor to detect liquid presence.
2Measurement precision
If a predetermined pattern is positioned between the illumination source and the target object, then detection accuracy for clear liquids is significantly improved, but the device complexity increases due to additional components
Solution Approach 1:
The predetermined pattern undergoes optical changes (distortions, refractions, bending of light lines) when viewed through liquid-filled vials. These changes in the optical properties of the pattern provide detectable signals that indicate the presence of liquid. The processor analyzes these pattern distortions to determine liquid presence, transforming an invisible refraction effect into visible pattern changes.
3Loss of information
If conventional backlighting without a pattern is used, then the system is simple to operate, but the system loses information about liquid presence in clear or small volume liquids
Solution Approach 1:
The predetermined pattern acts as an information carrier that is affected by the liquid. When light passes through the pattern and then through the liquid-filled vial, the liquid refracts the light, causing the pattern to appear distorted. This intermediary pattern preserves and transmits information about liquid presence that would otherwise be invisible, allowing the imager and processor to detect and analyze the liquid.
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
Effectively differentiates between vials with and without liquid by analyzing distortions in the pattern, improving detection accuracy for clear liquids and small liquid volumes, and can be extended to detect solids, foam, or bubbles.
Implementation Method 1
an illumination source positioned oppositely from the imager
Implementation Method 2
The processor may be programmed to determine whether there any distortions of the predetermined pattern based upon the refraction of light passing through the predetermined pattern and the target object
Data Source
AI summary
A machine vision system that uses an imager to capture an optical image of a target object that may contain a liquid. The target object is illuminated by an illumination source positioned oppositely from the imager and a predetermined pattern is positioned between the illumination source and the target object so that the imager will capture optical images of the background pattern through any liquid positioned in the target object. A processor is programmed to analyze captured images to detect any distortions of the pattern that are attributable to the presence of a liquid in the target object.