Virtual Measurement Simulation for Automated Optical Inspection Setup

The patent applies preliminary action by performing virtual simulations of the measurement setup before actual physical setup. Virtual models of the component, projector, and detector are created, and multiple measurement configurations are simulated in advance to identify optimal positions and parameters. This preliminary virtual preparation eliminates the need for time-consuming trial-and-error manual setup, directly resolving the contradiction between measurement optimality and setup time.

The patent uses copying by creating virtual copies (digital twins) of the physical measurement system components. A virtual model of the component to be measured is created, along with virtual models of the projector and detector. These virtual copies allow for rapid testing and optimization of measurement configurations without affecting the physical system, enabling fast determination of optimal setup parameters before actual measurement.

The patent determines optimal positions of the detection device through preliminary virtual simulations. The system evaluates multiple candidate positions virtually, assessing factors such as viewing angles, occlusions, and measurement quality metrics. The best position identified through simulation is then directly applied to the physical detection device, eliminating the need for difficult manual positioning and ensuring optimal viewing conditions.

The patent employs feedback by using the results of virtual measurements to guide physical setup. The simulation provides quantitative feedback about measurement quality at different positions, which is then used to adjust the physical detection device to the optimal position. This feedback loop ensures high positioning accuracy while simplifying the operation, as the system tells you exactly where to position the device rather than requiring manual optimization.

The patent creates simplified virtual models (copies) of the physical system that capture the essential geometric and optical characteristics without requiring full physical fidelity. These virtual models include the component geometry, projector characteristics, and detector parameters, allowing for efficient simulation of measurement configurations. The copying approach enables rapid virtual testing while keeping computational requirements manageable.

The patent systematically varies key parameters in the virtual simulation, such as detector position, projector orientation, and measurement patterns, to evaluate different measurement configurations. By focusing simulation efforts on the most influential parameters rather than modeling every detail, the system achieves high setup efficiency without excessive computational complexity. The simulation optimizes parameters like position coordinates and orientation angles to identify the best measurement setup.