Vision Detector System for Continuous Motion Inspection
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Solution Overview
Problem
Current industrial machine vision systems are limited by their slow operation speeds, high costs, inflexibility, and reliance on trigger signals, making them inefficient for real-time inspection of objects in continuous motion, especially in production line settings where multiple perspectives and synchronized output signals are necessary.
Innovation Solution
The development of a vision detector system that captures and analyzes multiple frames at high speeds, operates without trigger signals, and provides synchronized output signals, using a combination of ultra-sensitive imagers and digital signal processors to achieve reliable object detection and inspection with multiple perspectives, reducing costs and setup complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If machine vision systems use traditional photodetector arrangements, then the system is simple and inexpensive, but the system cannot analyze patterns of brightness from extended areas and requires multiple separate photodetectors that are hard to arrange
Solution Approach 1:
The patent merges multiple photodetector functions into a single two-dimensional array of photosensitive elements (imager). Instead of using separate photodetectors for different inspection points, the imager captures a complete image of the object, allowing simultaneous analysis of multiple features including brightness patterns from extended areas, edges, and other visual characteristics in a single measurement.
Solution Approach 2:
The patent transitions from one-dimensional point-by-point photodetector scanning to two-dimensional array imaging. The two-dimensional array of photosensitive elements captures spatial information across the entire field of view simultaneously, enabling pattern analysis of brightness distributions over extended areas that would require complex arrangements of multiple point photodetectors.
2Productivity
If photodetectors are used for inspection, then the system operates at high speed, but the system requires objects to be presented at known predetermined locations and is inflexible for line changeovers
Solution Approach 1:
The patent implements dynamic adaptability through software control of the imager and processing system. The system can dynamically adjust inspection parameters, regions of interest, and analysis algorithms based on the current product type, enabling flexible line changeovers without physical reconfiguration of photodetectors while maintaining high inspection speeds.
Solution Approach 2:
The two-dimensional imager serves multiple inspection functions simultaneously - detecting object presence, analyzing brightness patterns, identifying edges, and detecting features at various locations all within a single capture. This universal capability allows the same hardware to inspect different products on the production line by changing software parameters rather than physical setup.
3Measurement precision
If multiple separate photodetectors are arranged to inspect many points on an object, then comprehensive inspection is achieved, but the arrangement is difficult due to space limitations and crosstalk from light sources
Solution Approach 1:
The patent combines the functions of multiple separate photodetectors into a single two-dimensional array imager. This integration eliminates the space and interference problems associated with arranging multiple discrete photodetectors, as the array captures information from all inspection points simultaneously within its field of view without requiring physical separation or shielding from crosstalk.
Solution Approach 2:
The patent resolves the arrangement difficulty by transitioning from a distributed one-dimensional arrangement of multiple photodetectors to a consolidated two-dimensional array. The imager's pixel matrix provides comprehensive spatial coverage that would otherwise require many separate sensors, while the integrated structure eliminates crosstalk issues inherent in discrete photodetector arrangements.
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 faster, more reliable, and cost-effective object detection and inspection, allowing for flexible production line changes without manual repositioning of photodetectors, and provides accurate results even with objects in continuous motion.
Implementation Method 1
analyze patterns of brightness reflected from extended areas
Implementation Method 2
Each pixel measures the intensity of light falling on it during the shutter time
Data Source
AI summary
Disclosed are methods and apparatus for automatic optoelectronic detection and inspection of objects, based on capturing digital images of a two-dimensional field of view in which an object to be detected or inspected may be located, analyzing the images, and making and reporting decisions on the status of the object. Decisions are based on evidence obtained from a plurality of images for which the object is located in the field of view, generally corresponding to a plurality of viewing perspectives. Evidence that an object is located in the field of view is used for detection, and evidence that the object satisfies appropriate inspection criteria is used for inspection. Methods and apparatus are disclosed for capturing and analyzing images at high speed so that multiple viewing perspectives can be obtained for objects in continuous motion.