Windshield Residue Detection Using Polarized Light Imaging

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Solution Overview

Problem

Existing windshield residue detection methods are laborious, subjective, and inaccurate, making them sub-optimal for high-volume production and effective factory gating processes in automotive manufacturing.

Innovation Solution

A system utilizing polarized light and advanced image processing to detect and quantify windshield residues, employing a light source assembly, camera assembly, and computing device to generate a processing result indicative of cleanliness, with features like a dark box for controlled lighting and polarized blue light to enhance contrast and reduce interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual inspection methods are used for windshield residue detection, then the system complexity is reduced, but the measurement precision and productivity deteriorate

Engineering Contradiction:

Improvesystem complexityVSAvoidresidue detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated optical measurement system. A polarized light source illuminates the windshield while a camera captures reflected light, and image processing algorithms automatically detect and quantify residues. This substitution eliminates human subjectivity and improves measurement precision while maintaining manageable system complexity through modular design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes changes in light polarization parameters to detect residues. By measuring the degree and angle of polarization of reflected light at specific angles (50-70 degrees incidence, 15-45 degrees azimuth), the system creates sensitive contrast between clean and contaminated areas. This parameter-based approach enables objective, precise residue detection without complex mechanical inspection mechanisms.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If manual inspection methods are used, then the device complexity is lower, but the productivity and reliability deteriorate

Engineering Contradiction:

Improvesystem complexityVSAvoidinspection throughput

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces time-consuming manual inspection with automated optical imaging and digital processing. The system captures multiple polarization-direction images and processes them through algorithms that quickly identify residues, enabling high-volume production throughput while maintaining consistent inspection quality and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated optical inspection system operates continuously without interruption, capturing images and processing data in real-time during the manufacturing flow. This continuous operation eliminates the stop-start nature of manual inspection, improving productivity and ensuring consistent inspection coverage across high-volume production.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If manual inspection methods are used, then the system is simpler, but the reliability and objectivity of results deteriorate

Engineering Contradiction:

Improvesystem complexityVSAvoidinspection result consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent employs polarization optics to create objective, quantifiable measurements of windshield cleanliness. By measuring specific polarization parameters (degree and angle of polarization) at controlled angles, the system generates consistent, repeatable results that are not subject to human variability. The standardized optical parameters ensure reliable and comparable inspection results across different operators and time points.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system incorporates image processing feedback loops that automatically analyze captured images, compare them against predefined cleanliness criteria, and provide quantitative pass/fail determinations. This feedback mechanism ensures consistent application of inspection standards and maintains high reliability in inspection results by eliminating subjective judgment variability.

Inventive Principle:

Principle #23Feedback

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

Enables reliable, repeatable, and efficient detection and quantification of windshield residues, facilitating high-volume production and effective factory gating processes by ensuring consistent and accurate inspection results.

Implementation Method 1

directing polarized light toward the windshield

Methodology Applied

Scientific EffectPolarization: Polarisation

Implementation Method 2

generating an image based on the polarized light reflected from the windshield

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS20260002881A1System for windshield residue detection and quantification

Publication Date: 2026.01.01 TESLA INC

AI summary

Some embodiments of the present disclosure relate to systems and methods for detecting and quantifying residues on a surface, such as a windshield, for a vehicle. In some embodiments, a system may include a light source assembly, a camera assembly, and a computing device. The light source assembly can direct a polarized light toward the surface. The camera assembly can capture the polarized light reflected from the surface to generate an image. The computing device can process the image to generate a processing result indicative of cleanliness of the surface.