Bonding Plugged Honeycomb Structures with Optical Alignment
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Solution Overview
Problem
Existing methods for bonding plugged honeycomb structures require manual verification, leading to inefficiencies and potential misalignment of end faces, particularly when structures with different cell opening sizes are combined, resulting in increased pressure loss and reduced production efficiency.
Innovation Solution
A method involving imaging and light irradiation to confirm the alignment of end faces with a preset structure, allowing for automatic adjustment and bonding of honeycomb structures to ensure consistent orientation, eliminating the need for manual verification and reducing the likelihood of incorrect orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual verification is used to confirm end face alignment, then flexibility and adaptability are maintained, but productivity is reduced and human error increases
Solution Approach 1:
The patent replaces manual visual verification with an optical imaging system that captures images of end faces and uses automated image processing to confirm alignment. The imaging device and image processing unit substitute for human operators, enabling automated verification that maintains reliability while dramatically improving productivity.
Solution Approach 2:
The patent creates optical copies (images) of the end faces and compares them against preset structural patterns. By working with image data rather than physical inspection, the system enables automated verification that can be performed rapidly and consistently, resolving the contradiction between manual flexibility and automated efficiency.
2Productivity
If automated imaging and image processing are implemented, then productivity and alignment accuracy are improved, but device complexity increases
Solution Approach 1:
The imaging device serves multiple functions: capturing end face images, providing visual feedback for operators, and supplying data for automated image processing. This multi-functionality reduces the need for separate systems and minimizes overall device complexity while maintaining high productivity and accuracy.
Solution Approach 2:
The patent introduces an image processing unit as an intermediary between the imaging device and the bonding process. This intermediary layer handles the complex image analysis and alignment verification, allowing the core bonding system to remain relatively simple while still achieving automated, high-precision verification.
3Productivity
If end faces are not properly aligned, then manufacturing speed is maintained, but pressure loss increases due to incorrect orientation
Solution Approach 1:
The patent performs alignment verification through imaging and image processing before the bonding operation is completed. By confirming that end faces are correctly aligned with preset structures in advance, the system ensures proper orientation of inflow and outflow faces, preventing pressure loss issues while maintaining manufacturing speed through automated rapid verification.
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 enables efficient and accurate alignment of end faces, reducing manpower requirements and ensuring that all inflow end faces face the same direction, thereby minimizing pressure loss and enhancing production efficiency in manufacturing large honeycomb structures.
Implementation Method 1
imaging the end face on the one side with irradiating the end face with light beam
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3
AI summary
A method for bonding plugged honeycomb structures, the method includes the steps of: disposing each of the honeycomb structures each having different sizes of cell openings between one end face and the other end face so that the end face on one side faces the imaging device side, imaging the end face on the one side with irradiating the end face with light beam, and confirming whether the structure of the end face imaged is the same as a preset structure of the end face on the one side or not for the plugged honeycomb structures, and bonding the plugged honeycomb structure together at end faces so that the end faces on the one side face the same direction based on the structure of the end face confirmed. The direction of the end face of a plugged honeycomb structures can be inhibited efficiently from being reversed when a plurality of plugged honeycomb structures having different sizes of the cell openings between one end face and the other end face are bonded together.