The need for automated visual inspection in Japan is increasing due to labor shortages caused by the declining birthrate and aging population. We have developed an imaging system called One-shot BRDF (Bidirectional Reflectance Distribution Function), which can easily detect even micro-defects that are conventionally difficult to capture using parallel-beam illumination and an image sensor. By color-coding the direction of light, micro-defects can be instantly captured as a clear image. This paper proposes a novel micro-defect inspection system capable of automatically inspecting the surface of materials with complex shapes by mounting One-shot BRDF optics on the tip of a 6-degree-of-freedom (DOF) robot arm and scanning the material's surface. The 6-DOF robot arm can track the scanning trajectory and keep the optics squarely against the curved surface at a constant distance. We developed a simple algorithm to automatically determine the trajectory from the material's 3D CAD data so that the entire surface to be scanned can be inspected quickly and within the 6-DOF robot arm's range of movement. For high-speed and high-precision inspection, we built a nonlinear dynamic model of the 6-DOF robot arm and model-based control to track the trajectory while suppressing vibration. In scanning experiments using mirror-finished aluminum with a curved surface, the position and orientation control errors were sufficiently small in high-speed operation at the limit of the robot arm's performance. Several minute scratches on the mirror-finished aluminum could be detected and their locations were mapped as 3D CAD data.
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