Post-Tension Anchor Inspection Using Optical Depth Measurement
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Solution Overview
Problem
Existing methods for inspecting and sorting post-tension concrete anchors based on dimensional variations in their openings are inefficient, as they fail to accurately distinguish between anchors with minor and significant variations in the tapered inner surface, leading to incorrect sorting and potential structural issues.
Innovation Solution
An apparatus comprising a ramp, reference components, a depth measurement device, and a controller that uses movable and fixed cams to disengage anchors from a pin based on predetermined distance measurements, ensuring accurate sorting into acceptable or unacceptable chutes, thereby addressing the inefficiencies in existing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to examine anchors, then operational simplicity is maintained, but inspection accuracy and sorting precision deteriorate due to inability to accurately distinguish minor from significant dimensional variations
Solution Approach 1:
The patent replaces manual visual inspection and mechanical measurement methods with an automated optical measurement system. A depth measurement device (optical sensor) automatically measures the distance from the anchor surface to the tapered inner surface at multiple points, eliminating the need for manual calipers or visual estimation. This substitution of mechanical/manual systems with optical automation directly resolves the contradiction by achieving high measurement precision while maintaining relatively simple device complexity.
Solution Approach 2:
The inspection system is designed to automatically perform measurements and sorting decisions without requiring operator intervention. The depth measurement device automatically captures dimensional data, the controller automatically compares measurements against acceptance criteria, and the sorting mechanism automatically directs anchors to appropriate bins. This self-service automation resolves the contradiction by achieving high precision through automated measurement while keeping the overall system complexity manageable through integration.
2Productivity
If automated inspection systems are implemented to improve sorting accuracy, then measurement precision improves, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The patent divides the inspection and sorting process into distinct functional segments: (1) a depth measurement device for dimensional measurement, (2) a controller for data processing and decision-making, and (3) a sorting mechanism with movable and fixed cams for physical separation. This segmentation allows each component to be optimized independently and facilitates modular assembly, thereby improving productivity through specialized automation while managing device complexity through functional decomposition.
Solution Approach 2:
The controller serves as an intermediary between the depth measurement device and the sorting mechanism. It receives measurement data from the optical sensor, processes the information against predetermined acceptance criteria, and generates control signals to activate the appropriate cam mechanism for sorting. This intermediary layer enables automated high-speed inspection and sorting while keeping the overall system complexity manageable by centralizing intelligence in a single control unit rather than distributing it across multiple complex components.
3Measurement precision
If multiple measurement points are examined to ensure accurate sorting, then measurement precision improves, but inspection time increases, reducing productivity
Solution Approach 1:
The depth measurement device continuously scans the tapered inner surface of the anchor at multiple points in rapid succession, rather than performing discrete sequential measurements. The optical sensor can capture multiple depth values along the taper in a single inspection cycle, enabling comprehensive dimensional assessment without extending inspection time. This continuous measurement approach resolves the contradiction by achieving high measurement precision through multi-point data collection while maintaining fast inspection speeds.
Solution Approach 2:
The system performs preliminary measurements at multiple critical locations on the anchor before making a sorting decision. The depth measurement device pre-captures dimensional data from various points on the tapered inner surface, and the controller pre-evaluates this data against acceptance criteria before activating the sorting mechanism. This preliminary action ensures comprehensive dimensional assessment for high precision sorting while maintaining rapid inspection cycles by preparing all measurement and decision-making steps in advance.
Data Source
AI summary
An apparatus and method according to which a piece part is inspected and sorted. In several exemplary embodiments, the piece part is a post-tension concrete anchor. In an exemplary embodiment, the apparatus includes a reference component configured to engage the piece part by extending within an opening defined the piece part. The reference component extends within the opening by a first distance, the first distance being based on at least one dimension defined by the opening. A depth measurement device is configured to measure a second distance, which is a function of the first distance. A controller is configured to determine whether the second distance is within a predetermined range. If not, a bracket disengages the piece part from the reference component at a first location. If the second distance is within the predetermined range, the bracket disengages the piece part from the reference component at a second location.