Backlit Imaging for Plugged Honeycomb Body Defect Detection
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Solution Overview
Problem
Current inspection systems for plugged honeycomb bodies face challenges in providing low distortion imaging and efficient defect detection, often requiring type-tooling and being sensitive to environmental light, which increases inspection time and reduces precision.
Innovation Solution
The development of an imaging apparatus that uses a combination of backlit and directly illuminated imaging techniques, with a camera and lens system capable of capturing images with low parallax distortion, allowing for improved alignment and defect detection without the need for type-tooling, and enabling simultaneous inspection of both end faces of the honeycomb body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection systems are used for plugged honeycomb bodies, then imaging can be performed, but distortion is high and defect detection precision is reduced
Solution Approach 1:
The patent inverts the conventional imaging approach by placing the light source on the opposite side of the honeycomb body from the camera, creating a backlit imaging configuration. This inversion allows light to pass through the honeycomb structure, enabling detection of internal defects while minimizing distortion and eliminating the need for type-tooling.
Solution Approach 2:
The patent changes the illumination parameters by using a light source with specific characteristics (wavelength, intensity distribution) and positioning it at a distance that creates uniform backlighting. This parameter optimization enables high-precision defect detection without requiring complex type-specific fixtures.
2Adaptability or versatility
If type-tooling is used for inspection, then imaging can be performed for specific honeycomb types, but device complexity increases and adaptability decreases
Solution Approach 1:
The patent creates a universal inspection system that can inspect different types of plugged honeycomb bodies without requiring type-specific tooling. The backlit imaging configuration with a strategically positioned light source works across multiple honeycomb geometries, making the system multi-functional and highly adaptable.
Solution Approach 2:
The patent extracts the type-specific constraints by removing the need for custom fixtures and adapters for each honeycomb type. The simplified setup with just a camera, lens, and light source eliminates complex type-tooling while maintaining inspection capability across different honeycomb configurations.
3Productivity
If conventional imaging without backlighting is used, then inspection can be performed, but the system is sensitive to environmental light and inspection time increases
Solution Approach 1:
The patent applies preliminary anti-action by using backlighting to preemptively overcome environmental light interference. The light source is positioned and configured in advance to illuminate the honeycomb body from behind, creating a controlled illumination scenario that nullifies the effects of ambient light before it can interfere with the inspection process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces inspection time, enhances precision in defect detection, and allows for the identification of small defects, such as those sized 250 μm or smaller, while being less sensitive to environmental light, thereby improving the overall efficiency and accuracy of the inspection process.
Implementation Method 1
a part of the emitted light is obstructed from the first lens by the plugged honeycomb body, and another part of the emitted light is received by the first lens unobstructed by the plugged honeycomb body
Implementation Method 2
a first camera and a first lens optically coupled to a first camera, the first lens having a field of view
Data Source
AI summary
Inspection methods, apparatuses, and techniques are described herein for identifying defects in a plugged honeycomb body (100). The inspection apparatuses and methods herein utilize reduced distortion imaging to identify the defects in the plugged honeycomb body. Backlit and/or directly illuminated images (by e.g. first light source 308) of the plugged honeycomb body (100) can be captured (by e.g. camera 302) and analyzed to align (by e.g. actuators 306) the plugged honeycomb body (100) in an imaging apparatus and to identify the defects.