Vision Inspection System Rotary Platform AI Learning
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Solution Overview
Problem
Conventional vision inspection systems are labor-intensive, costly, and have low detection accuracy due to human error and limited flexibility, and machine vision systems face throughput issues and require time-consuming setup changes for different parts.
Innovation Solution
A vision inspection system with a rotary sorting platform and imaging devices that rotate parts to capture all sides without fixturing, using an AI learning module to update image analysis models for improved accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If machine vision inspection systems use cameras to image parts, then inspection automation is achieved, but throughput is limited due to the need to rotate or flip parts to view all sides
Solution Approach 1:
The patent introduces a transparent rotary sorting platform that allows imaging from multiple dimensions simultaneously. Multiple cameras positioned at different angles can capture images of all part surfaces without physical rotation, transforming a sequential single-dimension inspection process into a parallel multi-dimensional process, thereby resolving the throughput limitation while maintaining automation.
Solution Approach 2:
The transparent platform creates an optical copy effect where the bottom surface of parts can be imaged through the transparent material from below, eliminating the need to physically flip or rotate parts. This optical copying approach allows simultaneous imaging of all surfaces, increasing throughput while maintaining full inspection coverage.
2Measurement precision
If machine vision systems use fixturing for parts, then inspection accuracy is improved, but flexibility is reduced due to time-consuming setup changes when changing between various parts
Solution Approach 1:
The transparent rotary sorting platform serves multiple functions: it acts as a support structure, an imaging medium, and a positioning mechanism all in one. This universal component eliminates the need for part-specific fixturing while maintaining inspection accuracy through its optical properties and rotational capability, allowing quick adaptation to different part types without setup changes.
Solution Approach 2:
The patent replaces the mechanical fixturing system with an optical-based imaging approach through the transparent platform. Instead of physically constraining parts with mechanical fixtures that require adjustment, the system uses optical transparency and multi-angle camera positioning to achieve consistent imaging accuracy across different part types, significantly improving flexibility.
3Adaptability or versatility
If manual inspection systems use personnel to inspect parts, then flexibility in handling various parts is maintained, but detection accuracy is reduced due to human error and fatigue
Solution Approach 1:
The system enables self-service inspection where the transparent platform and multi-angle camera system automatically capture and process images of all part surfaces without human intervention. The AI learning module further automates defect detection and classification, eliminating human error and fatigue while maintaining the flexibility to inspect various part types through programmable analysis parameters.
Solution Approach 2:
The AI learning module implements feedback mechanisms by continuously learning from inspected images and improving defect detection accuracy over time. This adaptive feedback system maintains high detection accuracy across different part types by automatically adjusting analysis parameters, replacing manual inspection flexibility with intelligent automated adaptation.
Data Source
AI summary
A vision inspection system includes a rotary sorting platform rotated about an axis to rotate parts. The vision inspection system includes an inspection station positioned adjacent the rotary sorting platform including imaging devices to image different sides of the parts. The vision inspection system includes a vision inspection controller receiving images from the imaging devices and processing the images from the imaging devices based on an image analysis model. The vision inspection controller processes the images to determine inspection results for each of the parts. The vision inspection controller has an artificial intelligence learning module operated to update the image analysis model based on the images received from the imaging devices.