Optical inspection apparatus for moving articles

Abstract

An optical inspection system for articles moved by a conveyor, in which photo-electric transducers of one or more cameras are directed onto a transverse viewing area to detect light variations in individual articles. A threshold system permits correction for light signals in relation to the angular distance between the article being observed and the camera optical axis. A two-step inspection involves first detecting anomalous light levels, and subsequently detecting the size of each defect.

We claim: 
     
       1. An apparatus for optically inspecting articles, comprising: means for moving articles successively past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the articles as the articles pass through the viewing area;   means for directing radiant energy onto the articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area, in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area;   threshold means for generating article data signals by comparing the magnitude of the electrical signal produced by each transducer and a threshold reference value;   and control means operatively connected to the scanning camera means, said control means including viewing off-axis angle correcting means for varying the relationship between the threshold reference value and the electrical signals during each scan in relation to the angular distance between the transverse segment of the viewing area corresponding to each transverse segment of the viewing area being observed by each transducer and the camera optical axis.   
     
     
       2. The apparatus of claim 1 wherein said scanning camera means comprises: two cameras respectively mounted adjacent opposite sides of the inspection station, the cameras having optical axes that are directed downward and oppositely inward for repeatedly scanning the viewing area.   
     
     
       3. The apparatus of claim 2 wherein the control means comprises: coordinating means operatively connected to the two cameras for synchronizing the scanning of the two cameras.   
     
     
       4. The apparatus of claim 1 wherein the control means comprises: size means responsive to the generation of the article data signals associated with each article for determining size of defects in the articles.   
     
     
       5. The apparatus of claim 4 wherein the size means includes a counting means for counting the number of article data signals generated by defects in each article during a plurality of scans and for generating a size defect signal when the accumulated number exceeds a preset value. 
     
     
       6. The apparatus of claim 1 wherein the control means comprises: shade means for determining defects in the articles having different shades, and   size means for determining the size of the different shade defects.   
     
     
       7. The apparatus of claim 6 wherein the control means has adjusting means for adjusting threshold levels of the shade means and the size means to enable the apparatus to determine shade and size of the defects in the articles. 
     
     
       8. The apparatus of claim 1 wherein the threshold means includes a reference model that is mountable in the viewing area to simulate defectless articles and further includes reference signal generating means operatively connected to the scanning camera means for generating electrical representations of the magnitudes of the radiation received by the transducers from the reference model to produce the threshold reference value. 
     
     
       9. The apparatus of claim 8 further comprising and analog-to-digital signal generator operatively connected to the camera and responsive to the threshold means for generating digital signals representative of the analog difference between the electrical signals generated by the transducers from each scan of the articles and the threshold reference value. 
     
     
       10. The apparatus of claim 9 wherein the threshold means includes (1) scan memory means operatively connected to the analog-to-digital signal generator for storing the digital signals representative of the electrical representation of the radiation received from the reference model and (2) a digital-to-analog signal generator for receiving stored digital signals from the scan memory means and operatively connected to the analog-to-digital signal generator for generating the threshold reference value. 
     
     
       11. The apparatus of claim 1 for inspecting articles moving single file in a plurality of transversely spaced lanes, wherein the control means includes: (a) memory storage means having a number of storage elements corresponding to the number of viewing area segments;   (b) lane registration means for loading lane identification logic information into the storage elements corresponding with the viewing area segments in relationship to the location of the lanes with respect to the viewing area segments;   (c) memory read means for sequentially reading out the lane logic information from the storage elements in the same sequence that the viewing area segments are scanned;   (d) timing means operatively connected to the scanning camera and the memory read means for synchronizing the scanning of the viewing area and sequential reading out of the lane logic information; and   (e) logic means responsive to the generation of the article data signals from the scanning camera and the sequential reading out of the lane logic information for individually inspecting the articles in the plurality of lanes.   
     
     
       12. An apparatus for optically inspecting articles to detect shade variation defects in the articles, comprising: means for moving the articles in a plurality of transversely spaced lanes successively past an inspection station;   two scanning cameras mounted adjacent opposite sides of the inspection station, in which the cameras have optical axes that are directed downward and oppositely inward for repeatedly scanning a viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the articles as the articles pass through the viewing area;   means for directing radiant energy onto the articles within the viewing area;   each of said scanning cameras having an array of photo-electric transducers for receiving radiant energy from the viewing area for generating electrical signals, the magnitude of which correspond to the magnitude of radiation received by the photo-electric transducers;   threshold means responsive to the magnitude of the electrical signals for generating article defect signals by comparing the magnitude of the electrical signal produced by each transducer and a threshold reference value;   control means operatively connected to the scanning cameras for synchronizing the scanning of the two cameras to detect shade variation defects in the articles;   said control means including:   (a) memory storage means having a number of storage elements associated with each camera corresponding to a prescribed number of angular increments of the viewing area as viewed by each camera;   (b) lane registration means for loading lane identification logic information into the number of storage elements in relationship to the lateral location of the lanes with respect to the angular increments;   (c) memory read means for reading out the lane logic information;   (d) timing means operatively connected to the scanning cameras and the memory read means for synchronizing the scanning of the viewing area by both cameras and the read out of the lane logic information; and   (c) logic means responsive to the generation of the electrical signals from the scanning cameras and the reading out of the lane logic information for detecting in which lane a defective article occurs.   
     
     
       13. The apparatus of claim 12 wherein the control means includes; a viewing off-axis angle correcting means for varying the relationship between the threshold reference value and the electrical signals from the scanning cameras during each synchronized scan in relation to the angular ditance between the lane being observed and the optical axes of the cameras.   
     
     
       14. The apparatus of claim 12 wherein the control means comprises: size means responsive to the generation of the article defect signals from both cameras associated with corresponding lanes for determining the size of a defect.   
     
     
       15. The apparatus of claim 14 wherein the size means includes: a counting means corresponding with each lane for each camera for counting the number of electrical signals generated by defects in the articles located in each lane during a plurality of scans and for comparing the count to a preset value.   
     
     
       16. The apparatus of claim 12 wherein the control means comprises: shade means for determining defects having different shades; and   size means for determining the size of the different shade defects.   
     
     
       17. The inspection apparatus of claim 16 wherein the control means comprises: adjusting means for changing threshold levels of the shade means and the size means to enable the apparatus to continually modify the shade and size of the defects being determined.   
     
     
       18. The inspection apparatus of claim 12 wherein the photo-electric transducers generate an electrical representation of the magnitudes of radiation received by the transducers from the articles and wherein the threshold means generates an electrical threshold level that represents a base line electrical representation of the radiation received by the transducers when the articles are absent from the viewing area, in which the base line electrical representation varies from one lane to another in relation to the distance and angle of the lanes to the scanning camera. .[. 
     
     
       19.  An apparatus for optically inspecting articles, comprising: means for moving the articles successively past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a transverse viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the articles as the articles pass through the viewing area;   means for directing radiant energy onto the articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area;   shade comparator means for comparing the individual electrical signals generated by each transducer to a reference defect shade signal, and for generating an output signal when a defect is detected;   a plurality of register means for counting output signals associated with individual articles;   and size comparator means for monitoring the individual register means and for generating an electrical signal when the count for a register means exceeds a preset value..].   
     
     
       20. .Iadd.An apparatus for optically inspecting articles, comprising: means for moving the articles successively past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a transverse viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the articles as the articles pass through the viewing area;   means for directing radiant energy onto the articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area;   shade comparator means for comparing the individual electrical signals generated by each transducer to a reference defect shade signal, and for generating an output signal when a defect is detected;   a plurality of register means for counting output signals associated with individual articles;   and size comparator means for monitoring the individual register means and for generating an electrical signal when the count for a register means exceeds a preset value;   .[.The apparatus of claim 19 wherein.]. said scanning camera means comprising .[.comprises.].:   two cameras respectively mounted adjacent opposite sides of the inspection station in which the cameras have optical axes that are directed downward and oppositely inward for repeatedly scanning the viewing area.   
     
     
       21. The apparatus of claim 20 wherein the control means comprises: coordinating means operatively connected to the two cameras for synchronizing the scanning of the two cameras.   
     
     
       22. .Iadd.An apparatus for optically inspecting articles, comprising: means for moving the articles successively past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a transverse viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the articles as the articles pass through the viewing area;   means for directing radiant energy onto the articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area;   shade comparator means for comparing the individual electrical signals generated by each transducer to a reference defect shade signal, and for generating an output signal when a defect is detected;   a plurality of register means for counting output signals associated with individual articles;   and size comparator means for monitoring the individual register means and for generating an electrical signal when the count for a register means exceeds a preset value;   .[.The inspection apparatus of claim 19.]. wherein the photo-electric transducers generate an electrical representation of the magnitudes of radiation received by the transducers from the articles and wherein the threshold means generates an electrical threshold level that represents a base line electrical representation of the radiation received by the transducers when the articles are absent from the viewing area, in which the base line electrical representation varies in relation to the distance and angle of the scanning camera to the articles being inspected. .Iadd.   
     
     
       23.  An apparatus for optically inspecting a plurality of laterally spaced articles, comprising: means for moving the laterally spaced articles past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a viewing area extending transversely across the inspection station at a selected scan speed and frequency to optically inspect the plurality of laterally spaced articles as the articles pass through the viewing area;   means for directing radiant energy onto the laterally spaced articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area, in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area to optically inspect the laterally spaced articles as the article pass through the transverse viewing area;   defect detection means responsive to the electrical signals generated by the photo-electric transducers for generating article defect data signals for each of the laterally spaced articles passing through the transverse viewing area when the magnitude of electrical signals associated with each article reaches a preset defect threshold value;   a defect size determining means responsive to the defect data signals for determining sizes of the defects in each of the laterally spaced articles as the articles pass through the transverse viewing area;   wherein the defect size determining means includes a counting means associated with each laterally spaced article passing through the transverse viewing area for counting the number of defect data signals associated with each of the laterally spaced articles that are generated during a plurality of successive scans and for generating a reject signal when the accumulated number exceeds a preset value. .Iaddend. .Iadd.24. An apparatus for optically inspecting a plurality of laterally spaced articles, comprising:   means for moving the laterally spaced articles past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a viewing area extending transversely across the inspection station at a selected scan speed and frequency to optically inspect the plurality of laterally spaced articles as the articles pass through the viewing area;   means for directing radiant energy onto the laterally spaced articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area, in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area to optically inspect the laterally spaced articles as the articles pass through the transverse viewing area;   defect detection means responsive to the electrical signals generated by the photo-electric transducers from generating article defect data signals for each of the laterally spaced articles passing through the transverse viewing area when the magnitude of electrical signals associated with each article reaches a preset defect threshold value;   a defect size determining means responsive to the defect data signals for determining sizes of the defects in each of the laterally spaced articles as the articles pass through the transverse viewing area;   a plurality of defect detection means responsive to the electrical signals generated by photo-electric transducers for generating defect data signals for defects having different optical properties; and   a plurality of defect size determining means responsive to the defect data signals and corresponding with associated defect detection means for determining the size of the defects having different optical properties.   
     
     
        .Iaddend. .Iadd.25.  The apparatus for optically inspecting articles as defined in claim 24 wherein each of the defect size determining means includes a counting means associated with each laterally spaced article for counting the number of defect data signals that are generated for the corresponding optical property and for generating reject signals when the accumulated numbers exceed preset values. .Iaddend. .Iadd.26. The apparatus for optically inspecting articles as defined in claim 24 further comprising threshold adjusting means for individually adjusting the plurality of defect detection means with respect to a threshold to enable each defect detection means to detect a defect having a different optical property. .Iaddend. .Iadd.27. The apparatus for optically inspecting articles as defined in claim 24 further comprising threshold adjusting means for individually adjusting the plurality of defect side determining means with respect to a threshold to enable each defect size determining means to generate a reject signal for a different size and different 
     
     
        optical property of defects. .Iaddend. .Iadd.28.  An apparatus for individually optically inspecting a plurality of articles, comprising: means for moving the articles in unison passed an inspection station in laterally adjacent lanes;   scanning camera means mounted at the inspection station for repeatedly scanning a viewing area transversely across the adjacent lanes to individually inspect the articles as the articles move through the transverse viewing area in the adjacent lanes;   means for directing radiant energy onto the articles passing through the viewing area;   said scanning camera means having photo-electric means for receiving radiant energy from the viewing area for generating a plurality of electrical signals that correspond to the magnitude of the radiant energy received from the articles passing through the viewing area during each scan of the lanes;   defect detection means responsive to the magnitude of the electrical signals for generating article defect data signals when the magnitude reaches a preset value; and   defect size determining means responsive to the article defect data signals for counting the number of article defect data signals associated with each article during a plurality of scans and for generating a reject signal with respect thereto when the number of article defect data signals   
     
     
        associated with an article exceeds a preset value. .Iaddend. .Iadd.29. The apparatus for individually inspecting a plurality of articles as defined in claim 28, wherein the defect detection means includes more than one threshold means to enable the defect detection means to generate article defect data signals for more than one defect optical property for each article. .Iaddend. .Iadd.30. The apparatus for individually optically inspecting a plurality of articles as defined in claim 29 wherein the defect size determining means includes more than one counting means associated with each article for separately counting article defect signals associated with different shades to enable the defect size determining means to generate a reject signal for a relatively large light shade defect and for a small dark shade defect. .Iaddend. .Iadd.31. The apparatus for individually visually inspecting a plurality of articles as defined in claim 28 wherein the scanning camera means has a viewing lens having an optical axis intersecting the viewing area and wherein the defect detection means includes (1) a threshold means for generating a threshold reference value for each article and (2) a viewing off-axis correcting means for varying the relationship between the threshold reference value and the electrical signals during each scan in relation to the angular distance between the article and the camera optical axis. 
     
     
        .Iaddend. .Iadd.32.  An apparatus for optically inspecting a plurality of laterally spaced articles to determine if the articles have defects, comprising: means for moving the laterally spaced articles successively past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a transverse viewing area extending transversely across the inspection station at a selected scan speed and frequency to visually inspect the laterally spaced articles as the articles pass through the viewing area;   means for directing radiant energy onto the laterally spaced articles within the viewing area;   said scanning camera means having an array of photo-electric transducers for receiving radiant energy through a viewing lens having an optical axis intersecting the viewing area in which each photo-electric transducer is focused on a transverse segment of the viewing area for generating an electrical signal which corresponds to the magnitude of radiation received by the photo-electric transducer from its corresponding transverse segment of the viewing area;   shade comparator means for comparing the individual electrical signals generated by each transducer to a reference defect shade signal, and for generating an output signal when a defect is detected in one or more of the laterally spaced articles during each scan;   a plurality of register means for counting output signals associated with individual articles during successive scans of the laterally spaced articles;   and defect size comparator means for monitoring the individual register means and for generating an electrical size defect signal when the count for a register means exceeds a present value to determine the size of the detected defect. .Iaddend. .Iadd.33. The apparatus of claim 32 wherein said scanning camera means comprises:   two cameras respectively mounted adjacent opposite sides of the inspection station in which the cameras have optical axes that are directed downward and oppositely inward for repeatedly scanning the viewing area and the laterally spaced articles. .Iaddend. .Iadd.34. The apparatus of claim 33 wherein the control means comprises: coordinating means operatively connected to the two cameras for synchronizing the scanning of the two cameras to scan the transverse viewing area. .Iaddend. .Iadd.35. The inspection apparatus of claim 32 wherein the photo-electric transducers generate an electrical representation of the magnitudes of radiation received by the transducer from the articles and wherein the threshold means generates an electrical threshold level that represents a base line electrical representation of the radiation received by the transducers when the articles are absent from the viewing area, in which the base line electrical representation varies in relation to the distance and angle of the scanning camera to the laterally spaced articles being inspected. .Iaddend. .Iadd.36. An apparatus for optically inspecting a plurality of laterally spaced articles, comprising:   means for moving the laterally spaced articles in unison past an inspection station;   scanning camera means mounted at the inspection station for repeatedly scanning a viewing area transverse to the moving articles passing the inspection station to optically inspect the articles as the articles move through the transverse viewing area;   means for directing radiant energy onto the laterally spaced articles passing through the viewing area;   said scanning camera means having photo-electric means for receiving radiant energy from the viewing area for generating a plurality of electrical signals that correspond to the magnitude of the radiant energy received from the articles passing through the viewing area during each scan;   light shade defect detection means responsive to the magnitude of the electrical signals for generating light shade defect data signals when the magnitude of the electrical signals reaches a light shade defect threshold value;   dark shade defect detection means responsive to the magnitude of the electrical signals for generating dark shade defect data signals when the magnitude of the electrical signals reaches a dark shade defect threshold value;   a plurality of light shade defect size determining means, each associated with a corresponding laterally spaced article, and responsive to the light shade defect data signals identified with the corresponding article for counting the number of light shade defect data signals associated with the corresponding article during a plurality of scans and for generating a first reject signal with respect thereto when the number of light shade defect data signals associated with the corresponding article exceeds a preset light shade defect value; and   a plurality of dark shade defect size determining means, each associated with a corresponding laterally spaced article and responsive to the dark shade defect signals identified with the corresponding lane for counting the number of dark shade defect data signals associated with the corresponding article during a plurality of scans and for generating a second reject signal with respect thereto when the number of dark shade defect data signals associated with the corresponding article exceeds a preset light shade defect value. .Iaddend.