Lighting ToolboxLighting ToolboxDesign ProposalDesign Proposal

University of Michigan DearbornUniversity of Michigan Dearborn

ECE 498 ECE 498

Fall 2003Fall 2003

Dr. ShridharDr. Shridhar

Dr. ZhaoDr. Zhao

Students:Students:

Nick SitarskiNick Sitarski

Blaine ThopsonBlaine Thopson

Dave ChronicleDave Chronicle

Brandon HarrisBrandon Harris

Vladi GergovVladi Gergov

Advisor: Professor John MillerAdvisor: Professor John Miller

Machine Vision in IndustryMachine Vision in Industry

Electronic Component AnalysisElectronic Component Analysis Signature IdentificationSignature Identification Optical Character RecognitionOptical Character Recognition Object RecognitionObject Recognition Pattern RecognitionPattern Recognition Material InspectionMaterial Inspection Currency InspectionCurrency Inspection Medical Image AnalysisMedical Image Analysis

Typical SystemTypical System

Input SourceInput Source OpticsOptics LightingLighting Part SensorPart Sensor Frame GrabberFrame Grabber PC PlatformPC Platform Inspection SoftwareInspection Software Digital I/ODigital I/O Network ConnectionNetwork Connection X – Y Positioning tableX – Y Positioning table

Problems And SolutionsProblems And Solutions

Problem - Uneven Lighting Causes too Problem - Uneven Lighting Causes too bright a Part or Light Shape Interfering bright a Part or Light Shape Interfering With the ImageWith the Image

Solution - Diffused LightingSolution - Diffused Lighting

Problems and SolutionsProblems and Solutions

Problem - Un-Problem - Un-stable image of a stable image of a glossy target glossy target having an irregular having an irregular or complicated or complicated shape.shape.

Solution – Indirect Solution – Indirect Lighting Lighting

Problems and SolutionsProblems and Solutions

Problem - How to Problem - How to get a clear image get a clear image of an inscription of an inscription marking on shiny marking on shiny metal ?metal ?

Solution – Solution – Specular-Reflective Specular-Reflective LightingLighting

Problems and SolutionsProblems and Solutions

Problem - How to Problem - How to get a clear image get a clear image of an inscription of an inscription marking on shiny marking on shiny metal ? metal ?

Solution – Coaxial Solution – Coaxial Vertical LightingVertical Lighting

Problems and SolutionsProblems and Solutions

Problem - How to Problem - How to emphasize a small emphasize a small flaw or scratch on flaw or scratch on shiny metal? shiny metal?

Solution – Low-Solution – Low-angle Lightingangle Lighting

Problems and SolutionsProblems and Solutions

Problem - How to Problem - How to get clear outlined get clear outlined image of an image of an irregular shaped irregular shaped target? target?

Solution - Solution - Transmitted LightTransmitted Light

Problems and SolutionsProblems and Solutions

Problem - Visual acuity can be greatly Problem - Visual acuity can be greatly affected by light color (Bottle cap is affected by light color (Bottle cap is Red). Red).

Solution - Precise control over Solution - Precise control over intensity and light spectrum.intensity and light spectrum.

Output Channels Power

Linux Controller

CH-1 CH-2 CH-3 CH-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

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

Incandescent LightingIncandescent Lighting ContinuedContinued

Linux Server Sends PWM Signal to Control Linux Server Sends PWM Signal to Control IntensityIntensity

Circuitry Switches 1 of 4 Channels In Order to Circuitry Switches 1 of 4 Channels In Order to Control Intensity of Each Lamp Individually Control Intensity of Each Lamp Individually

Circuitry Sends Signals Back to the Linux Box to Circuitry Sends Signals Back to the Linux Box to Give Health Status of the SystemGive Health Status of the System

Standard Cable – Can be used with all other light controllers (5 Pin DIN Style)

LED light controller (Single Channel)

Ring Light adaptors

REDBLUEGREENIR

Output channel Can be Pulse Width Modulated and Strobed

Output Channel

Power

Linux Controller

Camera

Ring Light Ring Light AdaptorAdaptor

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

LED Ring LightingLED Ring Lighting

Design driver circuitry for LEDsDesign driver circuitry for LEDs Design voltage normalizer for lamp headsDesign voltage normalizer for lamp heads Design power supply / voltage regulatorDesign power supply / voltage regulator External trigger circuitryExternal trigger circuitry Design Micro Controller (Linux) interfaceDesign Micro Controller (Linux) interface Ring light and main circuit boardRing light and main circuit board Health status circuitryHealth status circuitry Design enclosureDesign enclosure

LED Ring Lighting ContinuedLED Ring Lighting Continued

System receives PWM signal from Micro System receives PWM signal from Micro Controller to control intensityController to control intensity

System has option to receive trigger for strobing System has option to receive trigger for strobing from Micro Controller or from external trigger from Micro Controller or from external trigger

Each LED unit will have a unique voltage Each LED unit will have a unique voltage regulator built into the LED ring itself regulator built into the LED ring itself

Health signals will be sent back to the Micro Health signals will be sent back to the Micro ControllerController

Light with Large Aspect RatioLight with Large Aspect Ratio

40 Watt Fluorescent LampHigh

Frequency Transformer

Driver Circuit @ 40 KHZ

40 KHz operating frequency

Intensity control via internet

Flicker free operation.

No interference with CCD camera.

Fluorescent Lighting Fluorescent Lighting ApplicationApplication

A circular 40 Watt fluorescent lamp A circular 40 Watt fluorescent lamp will be installed in a shadow box for will be installed in a shadow box for a transmitted lighting applicationa transmitted lighting application

This lamp will be controlled by the This lamp will be controlled by the fluorescent lamp controllerfluorescent lamp controller

A tubular style 40 Watt lamp will A tubular style 40 Watt lamp will also be constructed for applications also be constructed for applications with a large aspect ratio ie. Auto with a large aspect ratio ie. Auto windshield inspection etc..windshield inspection etc..

Fluorescent LightingFluorescent Lighting

Research lamp operating parametersResearch lamp operating parameters Design and implement high Design and implement high

frequency transformerfrequency transformer Design and implement switching and Design and implement switching and

power circuitry to drive transformerpower circuitry to drive transformer Design and implement intensity Design and implement intensity

control circuitrycontrol circuitry Design enclosure and circuit boardDesign enclosure and circuit board

Concept for Shadow BoxConcept for Shadow Box

40 Watt circular lamp enclosed in a 40 Watt circular lamp enclosed in a box with a white translucent diffuser box with a white translucent diffuser on topon top

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

Embedded Server Embedded Server (GNU/Linux box)(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

Web-Site LayoutWeb-Site Layout

Snap Shot of Lighted Area

Take New Snap Shot

Intensity Up

Intensity Down

Strobe Frequency

System Selection

System

Health

Web Sites ReferencedWeb Sites Referenced

www.whatis.comwww.whatis.com http://world.keyence.comhttp://world.keyence.com www.oemagazine.comwww.oemagazine.com www.emacinc.comwww.emacinc.com