Vision Inspection Image Fusion for Accurate Moving Defect Detection
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Solution Overview
Problem
Conventional optical inspection methods for moving inspection targets suffer from time delays in generating trigger signals due to operating system recognition, leading to inaccurate image capture and detection of defect locations.
Innovation Solution
A vision inspection apparatus and method that integrates an imaging device, motor, encoder unit, and image fusion unit to synchronize encoder data with image data, allowing precise capture and fusion of images from moving targets, including lighting adjustments based on synchronization signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a trigger signal is generated using an encoder counter and operating system recognition, then the camera can be controlled to capture images, but time delay occurs causing inaccurate image capture location
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing encoder count values corresponding to specific image capture locations before the actual capture process. The inspection computer stores a correspondence relationship between encoder count values and image capture locations in advance, allowing immediate retrieval during image capture without time-consuming real-time calculation or OS recognition delays.
Solution Approach 2:
The patent replaces the conventional mechanical/O.S.-based trigger signal generation system with a direct data-driven approach. Instead of using operating system recognition and sequential signal processing, the system directly queries pre-stored encoder count data to determine capture timing, eliminating the time delay inherent in OS-based signal recognition and processing.
2Reliability
If multiple images are captured under varying lighting conditions, then comprehensive inspection data is obtained, but inspection time and complexity increase
Solution Approach 1:
The patent applies dynamics by making the lighting conditions adaptive rather than static. The inspection system dynamically adjusts lighting based on real-time image quality assessment and defect detection needs. When defects are detected or specific lighting conditions are required, the system automatically modifies lighting parameters without requiring multiple predetermined captures, thus maintaining inspection completeness while improving efficiency.
Solution Approach 2:
The patent changes the parameter approach from fixed multiple captures to variable single capture. Instead of capturing multiple images under predetermined lighting conditions, the system captures images under current lighting conditions and dynamically adjusts lighting parameters based on real-time inspection requirements, reducing inspection time while maintaining data completeness.
Data Source
AI summary
The present disclosure relates to a vision inspection apparatus and a vision inspection method for inspecting defects in a moving inspection target. The vision inspection apparatus includes an imaging device configured to capture at least a part of an inspection target, a motor configured to move at least one of the imaging device and the inspection target so that a relative location of the imaging device and the inspection target change, an encoder unit configured to detect driving of the motor, an encoder signal processing unit configured to analyze an encoder signal transmitted from the encoder unit to generate encoder data, and an image fusion unit configured to fuse the encoder data to image data acquired by the imaging device to generate fused image data.