Virtual Camera Array for Web Inspection
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Solution Overview
Problem
Traditional web inspection systems utilize multiple cameras with underutilized image processing capacity, leading to inefficiency, increased costs, and limited flexibility in inspecting different types of webs and characteristics.
Innovation Solution
A system that combines image data from multiple cameras into a virtual camera data array, processed by fewer image processors, to efficiently align and synchronize data spatially, removing redundant information and enhancing analysis capabilities for defect detection and pattern inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple cameras are used to image portions of the web extending across the cross-web dimension, then the inspection coverage and measurement precision are improved, but the device complexity and processing costs increase due to underutilized image processor capacity
Solution Approach 1:
The patent combines image data from multiple cameras into a single virtual camera array, merging the functionality of multiple image processors into one. This consolidation maintains the inspection coverage provided by multiple cameras while reducing device complexity by eliminating redundant processing units. The virtual camera array integrates images from multiple cameras that capture overlapping portions of the web, creating a unified data structure that can be processed by a single image processor.
Solution Approach 2:
The single image processor in the virtual camera array system performs the work of multiple processors, achieving multi-functionality. This universal processor handles image data from all cameras in the array, removing redundant information and producing comprehensive inspection results. This approach maintains the enhanced measurement precision of multiple cameras while simplifying the overall system architecture.
2Power
If each camera is coupled to an individual image processor, then the processing capacity is distributed, but the processor efficiency decreases and costs increase due to wasted capacity
Solution Approach 1:
The patent merges multiple image processors into a single processing unit that handles the virtual camera array. This consolidation ensures that processing capacity is fully utilized by one processor rather than being distributed and underutilized across multiple processors. The single processor efficiently processes the combined image data from multiple cameras, eliminating the wasted capacity that occurs when each processor handles only a fraction of the total workload.
3Power
If multiple image processors are used to process image data from multiple cameras, then the processing power is increased, but the device complexity and costs increase
Solution Approach 1:
The patent combines the processing power of multiple image processors into a single processor that handles the virtual camera array. This merging maintains the increased processing power needed to handle data from multiple cameras while reducing device complexity by eliminating the need for multiple separate processing units and their associated control circuits.
4Measurement precision
If traditional multi-camera systems are used, then the inspection capability is enhanced, but the flexibility to inspect different types of webs and characteristics is limited
Solution Approach 1:
The virtual camera array creates a universal inspection system that can adapt to different web types and inspection characteristics. The single processed image data structure from the virtual array can be configured to inspect various features including surface imperfections, printed patterns, and dimensional characteristics across different web materials. This universal approach provides the enhanced inspection capability of multiple cameras while improving flexibility through a unified, reconfigurable processing system.
Data Source
AI summary
System and methods used to inspect a moving web (112) include a plurality of image capturing devices (113) that image a portion of the web at an imaging area. The image data captured by each of the image capturing devices at the respective imaging areas is combined to form a virtual camera data array (105) that represents an alignment of the image data associated with each of the imaging areas to the corresponding physical positioning of the imaging areas relative to the web. The image output signals generated by each of the plurality of image capturing devices may be processed by a single image processor, or a number of image processors (114) that is less than the number of image capturing devices. The processor or processors are arranged to generate the image data forming the virtual camera array.