1. Lighting Toolbox Design Proposal University of Michigan Dearborn ECE 498 Fall 2003 Dr. Shridhar Dr. Zhao Students: Nick Sitarski Blaine Thopson Dave Chronicle Brandon Harris Vladi Gergov Advisor: Professor John Miller

2. Machine Vision in Industry Electronic Component Analysis Electronic Component Analysis Signature Identification Signature Identification Optical Character Recognition Optical Character Recognition Object Recognition Object Recognition Pattern Recognition Pattern Recognition Material Inspection Material Inspection Currency Inspection Currency Inspection Medical Image Analysis Medical Image Analysis

3. Typical System Input Source Optics Lighting Part Sensor Frame Grabber PC Platform Inspection Software Digital I/O Network Connection X – Y Positioning table

4. Problems And Solutions Problem - Uneven Lighting Causes too bright a Part or Light Shape Interfering With the Image Problem - Uneven Lighting Causes too bright a Part or Light Shape Interfering With the Image Solution - Diffused Lighting Solution - Diffused Lighting

5. Problems and Solutions Problem - Un-stable image of a glossy target having an irregular or complicated shape. Problem - Un-stable image of a glossy target having an irregular or complicated shape. Solution – Indirect Lighting Solution – Indirect Lighting

6. Problems and Solutions Problem - How to get a clear image of an inscription marking on shiny metal ? Problem - How to get a clear image of an inscription marking on shiny metal ? Solution – Specular- Reflective Lighting Solution – Specular- Reflective Lighting

7. Problems and Solutions Problem - How to get a clear image of an inscription marking on shiny metal ? Problem - How to get a clear image of an inscription marking on shiny metal ? Solution – Coaxial Vertical Lighting Solution – Coaxial Vertical Lighting

8. Problems and Solutions Problem - How to emphasize a small flaw or scratch on shiny metal? Problem - How to emphasize a small flaw or scratch on shiny metal? Solution – Low-angle Lighting Solution – Low-angle Lighting

9. Problems and Solutions Problem - How to get clear outlined image of an irregular shaped target? Problem - How to get clear outlined image of an irregular shaped target? Solution - Transmitted Light Solution - Transmitted Light

10. Problems and Solutions Problem - Visual acuity can be greatly affected by light color (Bottle cap is Red). Problem - Visual acuity can be greatly affected by light color (Bottle cap is Red). Solution - Precise control over intensity and light spectrum. Solution - Precise control over intensity and light spectrum.

11. Output Channels Power Linux Controller CH-1CH-2CH-3CH-4 Typical Lamp Head (50 W Halogen Bulb) Each Lamp can be controlled independently via internet. Each channel can operate one Lamp head. Each channel connects to Lamp head via Lighting Tool Box standard 5 PIN DIN cable. Incandescent Lighting Camera

12. Incandescent Lighting Tasks Design Driver Circuitry For Lamps Design 200 Watt Power Supply and Voltage Regulator Research and Implement a Certain Incandescent Lamp (Most Likely Halogen) Design Micro Controller (Linux) Interface Circuitry Design Short Circuit Circuitry Design Circuit Board and Enclosure Health Status Circuitry

13. Incandescent Lighting Continued Linux Server Sends PWM Signal to Control Intensity Linux Server Sends PWM Signal to Control Intensity Circuitry Switches 1 of 4 Channels In Order to Control Intensity of Each Lamp Individually Circuitry Switches 1 of 4 Channels In Order to Control Intensity of Each Lamp Individually Circuitry Sends Signals Back to the Linux Box to Give Health Status of the System Circuitry Sends Signals Back to the Linux Box to Give Health Status of the System

14. Standard Cable – Can be used with all other light controllers (5 Pin DIN Style) LED light controller (Single Channel) Ring Light adaptors RED BLUE GREEN IR Output channel Can be Pulse Width Modulated and Strobed Output Channel Power Linux Controller Camera

15. Ring Light Adaptor Light Controller Camera Viewing area LED’s are arranged in a concentric ring around camera. Best suited for close inspection. Standard DC interface for all ring adaptors Each adaptor contains same type of LED’s. Linux Controller Types: RED BLUE GREEN IR Camera

16. LED Ring Lighting Design driver circuitry for LEDs Design driver circuitry for LEDs Design voltage normalizer for lamp heads Design voltage normalizer for lamp heads Design power supply / voltage regulator Design power supply / voltage regulator External trigger circuitry External trigger circuitry Design Micro Controller (Linux) interface Design Micro Controller (Linux) interface Ring light and main circuit board Ring light and main circuit board Health status circuitry Health status circuitry Design enclosure Design enclosure

17. LED Ring Lighting Continued System receives PWM signal from Micro Controller to control intensity System receives PWM signal from Micro Controller to control intensity System has option to receive trigger for strobing from Micro Controller or from external trigger System has option to receive trigger for strobing from Micro Controller or from external trigger Each LED unit will have a unique voltage regulator built into the LED ring itself Each LED unit will have a unique voltage regulator built into the LED ring itself Health signals will be sent back to the Micro Controller Health signals will be sent back to the Micro Controller

18. Light with Large Aspect Ratio 40 Watt Fluorescent Lamp High Frequency Transformer Driver Circuit @ 40 KHZ 40 KHz operating frequency Intensity control via internet Flicker free operation. No interference with CCD camera.

19. Fluorescent Lighting Application A circular 40 Watt fluorescent lamp will be installed in a shadow box for a transmitted lighting application A circular 40 Watt fluorescent lamp will be installed in a shadow box for a transmitted lighting application This lamp will be controlled by the fluorescent lamp controller This lamp will be controlled by the fluorescent lamp controller A tubular style 40 Watt lamp will also be constructed for applications with a large aspect ratio ie. Auto windshield inspection etc.. A tubular style 40 Watt lamp will also be constructed for applications with a large aspect ratio ie. Auto windshield inspection etc..

20. Fluorescent Lighting Research lamp operating parameters Research lamp operating parameters Design and implement high frequency transformer Design and implement high frequency transformer Design and implement switching and power circuitry to drive transformer Design and implement switching and power circuitry to drive transformer Design and implement intensity control circuitry Design and implement intensity control circuitry Design enclosure and circuit board Design enclosure and circuit board

21. Concept for Shadow Box 40 Watt circular lamp enclosed in a box with a white translucent diffuser on top 40 Watt circular lamp enclosed in a box with a white translucent diffuser on top

22. Embedded Server (GNU/Linux box) Used to control pulse width modulation signals, strobe signals, and health status signals Runs on an embedded computer with a flash drive and a our own from scratch design of the GNU/Linux operating system which will be streamlined for the embedded computer The embedded computer will run a daemon which will take its constantly take console inputs which can be passed via the console ( debugging ) or the web interface

23. Embedded Server (GNU/Linux box) This box will send out strobing signals for the LEDs, PWM signals for the incandescent bulbs and the fluorescent will be handled with hardware only The user will be able to select the different types of light, and change their properties via either the web site or the console at the box Code will be done in C/C++ to handle the PWM and strobing, along with the I/O of these signals To interface with the electronics USB standard will be used The GUI will be via a web site which will use PHP to pass commands the C/C++ daemon which will be doing the actual control

24. Web-Site Layout Snap Shot of Lighted Area Take New Snap Shot Intensity Up Intensity Down Strobe Frequency System Selection System Health

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