Workpiece Image Generation Device for Complex Surface Shapes
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Solution Overview
Problem
Existing workpiece image generation devices struggle to capture clear images of complex surface shapes due to uneven illumination and glare, with conventional techniques requiring multiple images at varying angles and lacking guidelines for optimal imaging settings, which can lead to image degradation and unsuitable area division.
Innovation Solution
A workpiece image generation device that rotates the workpiece and adjusts the imaging device's position/attitude relative to the workpiece to capture images with optimal luminance for each area, dividing the surface into partial areas based on machining information and synthesizing images to produce a composite image with consistent illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple images are captured at varied angles and added together, then images become less affected by extraneous light and surface reflection, but feature portions of the images inevitably degenerate as the image addition processing is repeated
Solution Approach 1:
The workpiece surface is divided into multiple partial areas based on surface shape information. Each partial area is processed independently by selecting the best image from multiple captures, rather than adding all images together. This segmentation prevents feature degradation while still reducing the impact of extraneous light and reflection.
Solution Approach 2:
Different imaging conditions are applied to different partial areas of the workpiece surface. For each partial area, the system selects the image with optimal luminance from multiple captures taken at varied angles. This local optimization ensures that each area achieves the best possible image quality without compromising overall feature integrity.
2Object-affected harmful factors
If images are captured with multiple illuminations to eliminate glare, then drum surface images without glare can be obtained, but a large number of illuminations are required and setting of partial areas with glare is so rough that suitable area division for complicated surface shape cannot be achieved
Solution Approach 1:
Surface shape information is acquired in advance from machining information before image capture. Based on this pre-acquired surface shape data, the workpiece surface is divided into partial areas, and imaging conditions are optimized for each area before actual image capture. This preliminary preparation eliminates the need for complex real-time illumination adjustments during imaging.
Solution Approach 2:
Instead of using multiple physical illuminations, the system uses surface shape information (a form of data copy) to simulate and predict optimal imaging conditions for each partial area. This virtual modeling approach replaces the need for multiple physical light sources and complex illumination settings.
3Measurement precision
If the position/attitude relationship between imaging device and workpiece is changed to optimize illumination, then clear surface images can be obtained, but establishing appropriate relationship between surface shape and light source influence becomes complex
Solution Approach 1:
The system uses acquired surface shape information as feedback to determine optimal imaging positions and attitudes for each partial area. By analyzing the surface shape data, the system automatically calculates and adjusts the imaging device's position and attitude to achieve optimal illumination conditions, eliminating manual trial-and-adjustment processes.
Solution Approach 2:
The system changes imaging parameters (position, attitude, and luminance selection) based on surface shape characteristics. For each partial area, the optimal image is selected from multiple captures taken at different angles, with selection criteria based on luminance values that account for the local surface geometry. This parameter optimization achieves clear surface images without complex manual adjustment.
Data Source
AI summary
A workpiece image generation device is provided with a machining information acquisition unit, an area division unit configured to virtually divide a surface area of the workpiece into partial areas based on the surface shape information, an image acquisition unit configured to acquire a plurality of images of the workpiece captured with different angles of irradiation on the workpiece as viewed from the imaging device, an area image selection unit configured to extract partial images individually from the plurality of images of the workpiece, based on the partial areas of the surface area of the workpiece, and select partial images corresponding to the individual partial areas from the plurality of extracted partial images, an image synthesis unit configured to generate a composite image of the workpiece obtained by synthesizing the partial images, and a composite image output unit configured to output the composite image of the workpiece.