Plane development of lateral surfaces for inspection systems

The problem of developing the lateral surfaces of a 3D object can arise in item inspection using automated imaging systems. In an industrial environment, these control systems typically work at high rate and they have to assure a reliable inspection of the single item. For compactness requirements it is not convenient to utilise three or four CCD cameras to control all the lateral surfaces of an object. Moreover it is impossible to mount optical components near the object if it is placed on a conveyor belt. The paper presents a system that integrates on a single CCD picture the images of both the frontal surface and the lateral surface of an object. It consists of a freeform lens mounted in front of a CCD camera with a commercial lens. The aim is to have a good magnification of the lateral surface, maintaining a low aberration level for exploiting the pictures in an image processing software. The freeform lens, made in plastics, redirects the light coming from the object to the camera lens. The final result is to obtain on the CCD: - the frontal and lateral surface images, with a selected magnification (even with two different values for the two images); - a gap between these two images, so an automatic method to analyse the images can be easily applied. A simple method to design the freeform lens is illustrated. The procedure also allows to obtain the imaging system modifying a current inspection system reducing the cost.