WO2024171185A1

WO2024171185A1 - Mobile system for visual inspection

Info

Publication number: WO2024171185A1
Application number: PCT/IL2024/050165
Authority: WO
Inventors: Michael GOTLIEB
Original assignee: Siemens AG; Siemens Corp
Current assignee: Siemens AG; Siemens Corp
Priority date: 2023-02-15
Filing date: 2024-02-12
Publication date: 2024-08-22
Anticipated expiration: 2025-08-15

Abstract

A mobile system for visual inspection includes a mobile case housing a camera to capture images of an item for inspection, a frame configured to have the camera mounted thereon and a processing unit to receive image data from the camera and to perform an inspection task on the item based on the received image data. The housing may further include an inspection surface on which to place an inspected item and which serves as a background for the item in the images captured by the camera.

Description

TITLE

MOBILE SYSTEM FOR VISUAL INSPECTION

FIELD

[0001] The present invention relates to visual inspection systems.

BACKGROUND

[0002] Inspection during production processes helps control the quality of products by identifying defects and acting upon their detection, for example, by fixing them or discarding defected parts, and is thus useful in improving productivity, reducing defect rates, and reducing re-work and waste.

[0003] Automated visual inspection systems are usually installed at inspection lines in production plants or other locations. Current visual inspection solutions are typically tailored to specific inspection lines or plants and, as such, include specifically designed components (such as cameras, light sources, and mechanical installation fixtures) that are positioned and mounted on to an inspection line according to specific environments and/or inspected products. These systems are not easily mobilized and cannot be easily used at several different locations.

SUMMARY

[0004] Embodiments of the invention provide a mobile system (also referred to as a “kit”) for automated visual inspection which can be easily and quickly assembled and/or taken apart and which can be easily mobilized between locations and can provide visual inspection capabilities at any desired location and in different environments, such as different inspection lines, offices, etc. Essentially, embodiments of the invention provide an ad hoc inspection system, which can be used, for example, as a professional tool to support human quality inspection service providers to augment their manual work with higher throughput and to provide professional digital documentation. In addition, embodiments of the invention provide factories with the ability to react in a professional way and with minimal set-up time, to ad-hoc quality challenges, which happen in each production line on a regular basis.

[0005] Embodiments of the invention provide a portable case which includes a built-in inspection surface and arm for mounting a camera for inspecting an item placed on the inspection surface. [0006] According to one embodiment, a mobile system for visual inspection includes a mobile case which houses a camera to capture images of an item for inspection and a processing unit to receive image data from the camera and to perform an inspection task on the item based on the received image data. The mobile case also houses at least one frame configured to have the camera mounted on and/or fixed to it.

[0007] In some embodiments, a mobile kit for visual inspection, includes a mobile case housing a processing unit for analyzing image data of an inspected item. The mobile case is designed to allow air circulation to cool the processing unit so that the processing unit can operate from within a mobile case without having to take the processing unit out of the case and without the processing unit overheating. The ability to have the processing unit work from within a mobile case facilitates installation time and enhances the option of mobilizing visual inspection solutions to different locations.

[0008] Thus, embodiments of the invention enable mobilizing an automated visual inspection system between various points on the same production line and/or between different production lines. Additionally, embodiments of the invention enable easily making a system available (e.g., for demonstration) to clients, suppliers, subcontractors, etc., as inspection tasks can be performed at any location. For example, production plants, which expect multiple use cases, can use a mobile kit, according to embodiments of the invention, to verify various use cases before investing in a permanent system. In another example, quality assurance (QA) teams can use a mobile kit, according to embodiments of the invention, for preforming ad hoc QA tests.

BRIEF DESCRIPTION OF THE FIGURES

[0009] The invention will now be described in relation to certain examples and embodiments with reference to the following illustrative figures so that it may be more fully understood. In the drawings:

[0010] Fig 1 schematically illustrates a mobile visual inspection system according to an embodiment of the invention;

[0011] Fig 2 schematically illustrates a mobile visual inspection system according to an additional embodiment of the invention;

[0012] Fig 3 schematically illustrates a mobile visual inspection system according to another embodiment of the invention;

[0013] Fig 4 schematically illustrates a mobile visual inspection system according to yet another embodiment of the invention; [0014] Fig 5 schematically illustrates a mobile visual inspection system operative according to an embodiment of the invention; and

[0015] Figs. 6A and 6B schematically illustrate different views of a mobile visual inspection system, according to embodiments of the invention.

DETAILED DESCRIPTION

[0016] In the following description, for purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the present invention. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details presented herein. Furthermore, well known features may be omitted or simplified in order not to obscure the present invention.

[0017] Unless specifically stated otherwise, as apparent from the following discussions, it is appreciated that throughout the specification discussions utilizing terms such as “analyzing”, "processing," "computing," "calculating," "determining," “detecting”, “performing inspection tasks” or the like, refer to the action and/or processes of a computer or computing system, or similar electronic computing device, that manipulates and/or transforms data represented as physical, such as electronic, quantities within the computing system's registers and/or memories into other data similarly represented as physical quantities within the computing system's memories, registers or other such information storage, transmission or display devices. Unless otherwise stated, these terms refer to automatic action of a processor, independent of and without any actions of a human operator.

[0018] Fig. 1 schematically illustrates a mobile system or kit 100 for automated visual inspection. Kit 100 includes a mobile case 10 which houses a camera 11 to capture images of an item for inspection and a processing unit 12 to receive image data from the camera and to perform inspection tasks on the item, based on the received image data.

[0019] Camera 11 may include a CCD or CMOS or other appropriate image sensor. Camera 11 may be a 2D or 3D camera. In some embodiments, camera 11 may include a standard camera provided, for example, with mobile devices such as smart-phones or tablets. In other embodiments, camera 11 may include specialized lenses or filters. Camera 11 may be a specialized camera, e.g., a camera for obtaining high resolution images or an ultra-violet, near- infra-red or infra-red specialized camera. In other embodiments camera 11 includes a non- optical camera, such as a neutron camera, a RADAR camera and the like.

[0020] Camera 11 may include a light source. In other embodiments, a light source is provided separately from the camera. [0021] Processing unit 12 may be a dedicated unit including, for example, one or more processors such as be a central processing unit (CPU), a graphics processing unit (GPU), a digital signal processor (DSP), a field-programmable gate array (FPGA), a microprocessor, a controller, a chip, a microchip, an integrated circuit (IC), or any other suitable multi-purpose or specific processor or controller.

[0022] Processing unit 12 receives image data (which may include data such as pixel values that represent the intensity of reflected light as well as partial or full images or videos) from camera 11, typically of inspected items, and runs processes to analyze the image data to perform inspection tasks such as, item presence, defect detection, defect location, quality assurance, sorting and/or counting, gating, etc.

[0023] Processing unit 12 may include or may be in communication with a memory, which may be located in the processing unit or remotely, e.g., in the cloud, to store at least part of the image data received from camera 11. The memory may include, for example, a random access memory (RAM), a dynamic RAM (DRAM), a flash memory, a volatile memory, a non-volatile memory, a cache memory, a buffer, a short term memory unit, a long term memory unit, or other suitable memory units or storage units.

[0024] Further housed within case 10 are frames 13A and 13B that can have camera 11 mounted and/or fixed onto them (for example, as illustrated in Fig. 5). In one example, frame 13A can be used to mount a camera in case 10, whereas frame 13B can be removed from case 10 and can be used for mounting a camera outside of case 10, e.g., on a production line. Frames 13A and 13B may provide one or more trajectories in different orientations or directions. In the example described in Fig. 1, frame 13A provides a trajectory along axis X and frame 13B provides another trajectory along axis Y, which is perpendicular to axis X. In other embodiments, frames 13A and 13B may include other trajectories. For example, frame 13A or 13B may form a half or full circle. Frames 13A and 13B may include, for example, a pipe of any shape. In one embodiment, frames 13A and 13B include an aluminum (or other suitable material) profile including, for example, a groove 113 for attachment of camera 11, as further detailed below.

[0025] Case 10 is typically a ruggedized case and includes at least some rigid sides, such as sides 101 and 102. Case 10 may provide supporting infrastructure for integration of a visual inspection system into the production line and obviates the need for additional supporting infrastructure, which is usually required when integrating an inspection system into a production/inspection line. [0026] Case 10 is compact and may be easily mobilized. In some embodiments, which are described below, case 10 includes one or more handle(s) (possibly telescopic or foldable handles) for easily carrying the case and/or one or more mobilizing mechanism, such as wheels. In some embodiments, case 10 may be fashioned as atrolly or carryon suitcase, for easy travel. Components of the system housed within case 10, including the case itself, may weigh less than, e.g., 20 Kg, easily within the weight range of normal airline aviation luggage without surcharge, thus facilitating mobilization of inspection systems according to embodiments of the invention.

[0027] Fig. 2 schematically illustrates a mobile visual inspection system, according to additional embodiments of the invention.

[0028] Mobile kit 200 includes a case 20 housing a camera and processing unit (not shown) and a frame 23 for attaching the camera. Kit 200 further includes an inspection surface 24 on which to place an item for inspection. Inspection surface 24 may serve as a background for the item in the images captured by the camera. The inspection surface 24 may be colored (e.g., having a dark or light color) to provide a suitable background for the environment and item being inspected. In some embodiments, inspection surface 24 includes several (e.g., at least two) differently colored planes. Thus, a front plane of the inspection surface 24 may be colored white (or another light color) whereas a back plane of the inspection surface 24 may be colored black (or other dark color). Having the option of using several differently colored planes as a background for inspection, enables using a single system to inspect several different items, thereby enhancing flexibility of inspection.

[0029] Inspection surface 24 fits closely within the frame 23 and is situated on top of and typically covering any other components housed within case 20. The inspection surface 24 may be designed for being easily lifted from case 20. For example, inspection surface 24 may include a niche 214 into which a user’ s fingers may be inserted to lift the inspection surface 24 from case 20, e.g., to expose other components housed within case 20, such as the camera and processing unit.

[0030] A mobile kit having additional components is schematically illustrated in Fig. 3. Kit 300 includes a case 30 which houses a camera 31, a processing unit 32 and a frame 33. Case 30 may include a handle 38 and wheels 39 to facilitate mobilization of kit 300. The components of kit 300 may be placed within protected bays or compartments (e.g., compartments with foam padding) within case 30 and case 30 may be ruggedized to protect the components housed within it, for example, while the case is being mobilized. [0031] Kit 300 may further include a fastening device 37 which is moveably connected to frame 33, namely, fastening device 37 may move along frame 33, e.g., along groove 313, while being connected to the frame 33. Typically, fastening device 37 is loosened (e.g., unscrewed) so that it can be moved along groove 313 and is tightened (e.g., screwed tightly) to affix it to frame 33 at a desired location along the frame. Fastening device 37 (which may include elements such as clamps, bolts, nuts, t-nuts, sliding blocks, springs, connectors, brackets, etc.) is designed to attach camera 31 to frame 33, such that once camera 31 is attached to fastening device 37, camera 31 may be moved to a desired location along frame 33 and may be fixed to the desired location.

[0032] Also included in kit 300 is an arm 36 configured to attach to frame 33 at one end 36’ of the arm and to camera 31 at an opposing end 36”of the arm. Typically, arm 36 is configured to attach to fastening device 37 at the one end 36’ of the arm and to camera 31 at the opposing end 36”. The arm 36 may include a joint such as hinge 316 to enable arm 36 to bend and/or rotate and enable camera 31 (which is attached to it) to be positioned at different heights and/or angles, e.g., relative to an inspected item.

[0033] In some embodiments, case 30 includes an electrical hub 302 for connecting and/or powering devices. Electrical hub 302 may be powered via connection to the electric grid and/or by a local power source, such as a battery (which may be housed in case 30).

[0034] Components from the kit and/or external devices may be connected to each other via electrical hub 302, as further detailed below.

[0035] Kit 400, which is schematically illustrated in Fig. 4, may include one or more niches or pockets for storing accessories, for example, an antiglare cover to prevent glare from a light source possibly attached to a camera, electrical cables, etc. In the example schematically illustrated in Fig. 4, case 40 includes a case cover 404 that, when closed, can fold over and protect the components housed within the case 40 (for example, frame 43 and inspection surface 44). Case cover 404 may include pockets 414, 424 and 434 for holding accessories such as electric/communications cables 4. Cables having different lengths and purposes, may be supplied with kit 400. For example, two sets of cables may be provided with kit 400, a set of one or more short cables for use when a camera is installed or mounted on case 40 and another set of longer cable(s) for use when the camera is installed or mounted outside case 40, e.g., on a production line.

[0036] When case cover 404 is opened, pockets 414, 424 and 434 are revealed and can be easily accessed by a user. [0037] During mobilization of the kit 400, e.g., by using handle 48 and/or wheels 49, case cover 404 is typically closed to enclose and protect the components housed within case 400.

[0038] A mobile kit for visual inspection operable according to an embodiment of the invention, is schematically illustrated in Fig. 5. During operation, case 50 may be laid down on a table or other surface at a production line, e.g., during a demonstration or during QA tests. Case cover 505 is opened, revealing the components housed within case 50 (e.g., components as described herein). Inspection surface 54 may be lifted revealing camera 51 and camera arm 56 packed in padded compartments (not shown). Camera 51 and arm 56 may be removed from their compartments and may be set up. For example, camera 51 may be latched on to one end of camera arm 56 while the other end of camera arm 56 is latched on to frame 53, e.g., via fastening device 57. Camera 51 may be electrically connected to a processing unit (e.g., as described herein), for example, via electrical hub 502. Other devices, such as described below, may be connected to the processing unit via electrical hub 502.

[0039] Inspection surface 54 is replaced and an item 501 can be placed on inspection surface 54 to be imaged by camera 51 and to be analyzed by a processing unit for inspection tasks, such as, presence of item, defect detection, defect location, quality assurance, sorting and/or counting, gating, etc.

[0040] Image data of item 501 may be transmitted to an on-board processing unit (e.g., a dedicated processing unit housed within the case 50) for analysis and/or to an external processor or other device, which may be in electric communication with camera 51. Processing may include outputting analysis results, e.g., on a user interface device, as well as producing professional digital (or other) documentation.

[0041] Network protocols such as FTP (File Transfer Protocol) may be used to transmit images and/or other information.

[0042] Systems according to embodiments of the invention can provide offline processing as well as the option of integrating into an online system.

[0043] Electric communication between components such as camera 51, an on-board processing unit and external devices, may be wireless and/or via cables, e.g., via electrical hub 502.

[0044] In some embodiments, components of a mobile kit may be connected via a programmable logic controller (PLC), typically used in manufacturing processes, e.g., for data handling, storage, processing power, and communication capabilities. A PLC may be in communication with a processing unit, a storage device, a user interface device, a camera and/or other components, via electrical hub 502, using USB, Ethernet, appropriate cabling, etc. [0045] In some embodiments, a camera may be connected to the processing unit via electrical hub 502. In some embodiments, an external user interface device may be connected to a processing unit via electrical hub 502. A user interface device that can be connected to the processing unit may include a display, such as a monitor or screen, having a graphic user interface (GUI) for displaying images, instructions, recommendations and/or notifications to a user (e.g., via text or other content displayed on the monitor). The user interface device may be designed to receive input from a user. For example, the user interface device may include a monitor and keyboard and/or mouse and/or touch screen, to enable a user to input feedback, instructions, etc. The processing unit may be controlled via the user interface device.

[0046] In some embodiments, an external storage device, such as a server including for example, volatile and/or non-volatile storage media, such as a hard disk drive (HDD) or solid- state drive (SSD), may be connected to components of the kit, locally or remotely, e.g., in the cloud. The external storage device may store image data and/or executable instructions to be executed by the processing unit, e.g., to perform inspection tasks. The storage device may be used for local data storage and/or if necessary, for exporting data and/or results of analysis. [0047] In one embodiment, which is schematically illustrated in Fig. 6A (front view) and Fig. 6B (a view from the rear), a mobile kit for visual inspection includes a mobile case housing a processing unit configured to analyze image data of an inspected item, where the mobile case is designed to allow air circulation to cool the processing unit.

[0048] A mobile kit for visual inspection includes a mobile case 60 housing a processing unit 62. The case may further house components such as an electrical hub (e.g., for connecting devices to the processing unit) and other components, such as described herein.

[0049] In one embodiment, the case 60 includes a ventilating structure 611 to allow air circulation to cool the processing unit 62. The ventilating structure 611 may include openings 613 in the case wall 603 and possibly one or more fan 614 to allow and possibly enhance air circulation. Openings 613 may be covered by (optionally removeable) waterproof or other coverings to protect the ventilating structure and the processing unit 62 while case 60 is being mobilized, e.g., by use of handle 68 and/or wheels 69.

[0050] Having a ventilating structure as part of the mobile case housing the kit, facilitates mobility of the kit.

[0051] As exemplified above, embodiments of the invention facilitate mobilization of an automated visual inspection system, e.g., between various points on the same production line and/or between different production line and/or to clients, suppliers, subcontractors, etc., thereby providing flexible and on-demand inspection capabilities and providing a professional inspection tool for ad hoc inspection.

Claims

1. A mobile system for visual inspection, the system comprising: a mobile case, the case housing: a camera to capture images of an item for inspection; a frame configured to have the camera mounted thereon; a processing unit to receive image data from the camera and to perform an inspection task on the item based on the received image data.

2. The mobile system of claim 1 comprising an inspection surface on which to place the item and which serves as a background for the item in the images captured by the camera.

3. The mobile system of claim 2 wherein the inspection surface is configured to closely fit within the frame.

4. The mobile system of claim 2 wherein the inspection surface is configured to be lifted out from the case.

5. The mobile system of claim 2 wherein the inspection surface comprises at least two differently colored planes.

6. The mobile system of claim 1 wherein the frame provides at least two trajectories in different orientations.

7. The mobile system of claim 1 wherein the frame is configured to be removed from the case, to mount a camera outside of the case.

8. The mobile system of claim 1 comprising a fastening device moveably connected to the frame, the fastening device configured to attach the camera to the frame.

9. The mobile system of claim 1 comprising an arm configured to attach to the frame at one end of the arm and to the camera at an opposing end of the arm.

10. The mobile system of claims 8-9 wherein the arm is configured to attach to the fastening device at the one end of the arm.

11. The mobile system of claim 9 wherein the arm comprises a hinge to enable the camera to be positioned at different heights and angles.

12. The mobile system of claim 1 wherein the camera comprises a light source.

13. The mobile system of claim 1 wherein the case comprises an electrical hub configured to connect an external user interface device to the processing unit.

14. The mobile system of claim 1 wherein the case comprises an electrical hub configured to connect components of the system.

15. The mobile system of claim 1 comprising a niche configured to store an electrical cable .

16. The mobile system of claim 1 wherein the case comprises rigid sides.

17. The mobile system of claim 1 wherein the case comprises a handle by which to carry the system.

18. The mobile system of claim 1 comprising wheels by which to mobilize the case.

19. The mobile system of claim 1 wherein the case comprises a ventilating structure to allow air circulation to cool the processing unit.

20. A mobile system for visual inspection, the system comprising: a mobile case housing a processing unit configured to analyze image data of an inspected item, the mobile case configured to allow air circulation to cool the processing unit.

21. The mobile system of claim 20 wherein the case comprises an electrical hub configured to connect a device to the processing unit.

22. The mobile system of claim 20 wherein the case houses a camerato capture images of an item for inspection and a frame configured to have the camera mounted thereon.