Brush Seal Bristle Angle Inspection Using Digital Imaging
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Solution Overview
Problem
Manual inspection of brush seal bristle angles is subjective, time-consuming, and non-repeatable, necessitating improved systems and methods for automated bristle configuration determination.
Innovation Solution
A system comprising a brush seal support, cameras with electronic optical sensors, and a computer to automatically determine bristle configurations by capturing and processing images of the brush seal, utilizing algorithms to calculate bristle angles and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection using transparent protractor is used, then simplicity of equipment is maintained, but measurement precision and repeatability deteriorate
Solution Approach 1:
The patent replaces manual mechanical measurement tools (transparent protractor) with an automated optical measurement system consisting of digital camera, fixture with reference lines, and image processing software. This substitution eliminates subjective manual measurement while achieving high precision bristle angle determination through digital image analysis.
Solution Approach 2:
The patent creates a digital copy of the bristle configuration by capturing images with a digital camera. The physical bristle arrangement is replicated in digital form, allowing for precise measurement and analysis without physically touching or disturbing the actual bristles. The digital image serves as a copy that can be measured repeatedly with high precision.
2Productivity
If manual inspection method is used, then device complexity is low, but productivity and inspection speed deteriorate
Solution Approach 1:
The patent replaces slow manual inspection processes with automated optical capture and digital image processing. The digital camera rapidly captures bristle configurations, and software automatically analyzes angles and dimensions, dramatically increasing inspection speed while reducing human labor time.
Solution Approach 2:
The inspection system performs self-measurement and self-analysis. The digital camera automatically captures images, and the image processing software autonomously determines bristle angles and configurations without requiring manual intervention for each measurement, enabling high-speed automated inspection.
3Reliability
If manual inspection is used, then ease of operation is maintained, but reliability and repeatability of inspection results deteriorate
Solution Approach 1:
The patent replaces subjective manual judgment with objective digital measurement. The system consistently applies the same measurement criteria through software algorithms, eliminating variability between different inspectors and ensuring repeatable results across multiple inspections.
Solution Approach 2:
The system provides automated feedback through digital image analysis, objectively reporting bristle angle measurements and compliance status. This eliminates subjective interpretation and ensures consistent evaluation criteria are applied every time, improving reliability and repeatability of inspection results.
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
Provides accurate, repeatable, and efficient inspection of brush seal bristle configurations, ensuring compliance with design tolerances.
Implementation Method 1
capturing an image of the brush seal with the camera
Data Source
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AI summary
A method is provided for inspecting a device comprising a plurality of bristles. During this method, image data provided from an electronic optical sensor is received. The image data is indicative of an image of at least a portion of the bristles. A bristle configuration (e.g., an angle) of at least one of the bristles (e.g., an average bristle) in the image is determined by processing the image data with a computer processor.