Vision Inspection Controller for Cross-Protocol Part Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inspection systems for part manufacture are labor-intensive, costly, and prone to human error, with machine vision systems being time-consuming and requiring expensive hardware and software, and often suffer from limited communication between components using different protocols.
Innovation Solution
A vision inspection system integrated with a communication network that includes an imaging device, a vision inspection controller communicatively coupled to a machine controller, using a first communication protocol to process images, determine inspection results, and trigger machine motive devices for part removal or movement, enabling efficient and accurate inspection and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection systems are used, then labor intensity and cost are high, but detection accuracy is low and product consistency is poor
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated machine vision system that uses imaging devices and image processing algorithms to detect defects, thereby eliminating human labor while improving detection accuracy and product consistency
Solution Approach 2:
The inspection system performs self-inspection by automatically capturing images, processing them through algorithms, and generating inspection results without requiring human operators, enabling the system to serve itself in the inspection process
2Measurement precision
If machine vision inspection systems are used, then detection accuracy is improved, but inspection time increases and hardware/software cost is high
Solution Approach 1:
The system processes only the necessary portions of images at appropriate levels of detail, avoiding complete exhaustive analysis of every pixel, thereby reducing inspection time while maintaining sufficient detection accuracy for quality control purposes
Solution Approach 2:
The inspection system operates in periodic cycles with image capture, processing, and result generation occurring in discrete time intervals, enabling efficient batch processing that reduces overall inspection time compared to continuous frame-by-frame analysis
3Adaptability or versatility
If different communication protocols are used between components, then system compatibility is reduced, but communication capability is limited
Solution Approach 1:
The patent introduces a communication conversion module that acts as an intermediary between components using different communication protocols, translating and converting signals between protocols to enable seamless communication while preserving all information exchange capabilities
Data Source
AI summary
A vision inspection system includes an imaging device that is configured to image parts being inspected. The vision inspection system includes a vision inspection controller that is configured to be communicatively coupled to a machine controller of the part manufacture machine by a communication network. The vision inspection controller communicates with the communication network using a first communication protocol. The vision inspection controller creates an absolute path directory at the machine controller. The vision inspection controller receives an image from the imaging device. The vision inspection controller communicates a first trigger to the absolute path directory upon receipt of the image from the imaging device. The vision inspection controller processes the image from the imaging device to determine inspection results for a first part of the parts. The vision inspection controller sends at least one of the image or the inspection results to the machine controller.