Windshield Optical Defect Detection via Power-Geometric Threshold
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Solution Overview
Problem
Current methods for detecting optical defects in windshields are inadequate as they often fail to detect defects visible only to human eyes, leading to rejected products and production losses, and can behave differently depending on the inspection system used, making it challenging to find a universal detection criterion compatible with manufacturing line configurations.
Innovation Solution
A computer-implemented method that processes digital image maps of optical power to detect regions with varying intensity, computes representative geometric dimensions and optical power values, and identifies defects based on a product threshold of 2.9·10−4, which corresponds to minimal distortion visible to drivers, allowing for detection of defects that may be overlooked by common inspection systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If standard inspection systems are used to detect optical defects, then manufacturing efficiency is maintained, but detection precision deteriorates because many defects visible to human eyes are missed
Solution Approach 1:
The patent changes the detection parameter from standard optical power mapping to a specific product threshold (2.9·10−4) that corresponds to minimal distortion visible to drivers. This parameter change enables detection of previously undetected defects without requiring complex new equipment, thus improving precision while maintaining manufacturing efficiency
Solution Approach 2:
The patent uses existing digital image maps of optical power that are already captured during manufacturing, copying this data to apply the new detection criterion. This avoids adding new inspection equipment, maintaining productivity while improving defect detection through computational analysis of existing data
2Reliability
If multiple different inspection systems are used, then comprehensive defect coverage is attempted, but reliability deteriorates because systems behave differently and may miss the same defects
Solution Approach 1:
The patent creates a universal detection criterion (product threshold of 2.9·10−4) that can be applied across different inspection systems and manufacturing line configurations. This single criterion provides consistent defect detection regardless of the specific inspection system used, improving reliability without increasing device complexity
Solution Approach 2:
Instead of adapting inspection systems to detect different defect types, the patent inverts the approach by establishing a detection criterion based on human visual perception thresholds. This inversion ensures that any system applying this criterion will detect defects visible to drivers, regardless of system-specific variations
3Ease of manufacture
If existing optical power mapping facilities are used, then ease of manufacture is improved, but detection precision deteriorates because they cannot detect driver-visible defects
Solution Approach 1:
The patent makes the existing optical power mapping facilities serve a new function by applying the product threshold criterion to their output data. The existing facilities continue to operate as before, but their data is now analyzed with the new criterion to detect previously missed defects, improving precision without sacrificing ease of manufacture
Solution Approach 2:
The patent changes how existing facilities are utilized by introducing a specific product threshold (2.9·10−4) as the detection criterion. This parameter change transforms the output of standard optical power mapping into actionable defect detection results, improving precision while maintaining ease of manufacture
Data Source
AI summary
A method for detecting optical defects within a windshield. The method takes, as input, a digital image map of the intensity of optical power of a windshield, and provides, as output, a digital image map of optical defects. The method includes (a) an image processing of the digital image map of optical powers for detecting and delimiting regions that differs in intensity of optical power; (b) computing, for each detected regions, a representative geometric distance and a representative value of the optical power; (c) computing an image map of the detected regions for which the product between the representative geometric distance and the representative value of the optical power is equal or superior to 2.9·10−4.