3D Laser Scanner for High Voltage Cable End Surface Inspection
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Solution Overview
Problem
Current methods for inspecting the quality of high voltage cable ends, particularly in on-site settings, are inadequate as they rely on human visual inspection, which is prone to errors and lacks data for future quality revisions and fault analysis, and existing automated systems are too large and cumbersome for on-site use.
Innovation Solution
A method and system utilizing a non-contact 3D laser scanner to create a continuous 3D surface geometry measurement of the cable end, comparing it to predefined acceptance thresholds to determine quality, allowing for accurate and efficient assessment of the surface quality, even in confined on-site environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If human visual inspection is used to determine surface quality, then the method is simple and requires no complex equipment, but the inspection accuracy is low and defects may be missed
Solution Approach 1:
The patent replaces the mechanical human visual inspection system with an optical measurement system using a laser scanner. The laser scanner emits laser lines that are captured by a camera to create 3D surface geometry measurements, automatically detecting surface defects without human intervention. This substitution dramatically improves measurement precision while maintaining operational simplicity.
2Measurement precision
If a large automated scanning system is used for surface inspection, then the measurement precision is high, but the device is too large and cumbersome for on-site use
Solution Approach 1:
The patent divides the scanning system into portable, handheld components that can be easily moved to different cable ends for inspection. The laser scanner and camera are integrated into a compact unit that operators can carry to on-site locations, eliminating the need for large fixed scanning infrastructure while maintaining high measurement precision through multiple sequential scans.
Solution Approach 2:
The system performs preliminary 3D mapping of the cable end surface before final defect analysis. By first capturing the overall surface geometry and then focusing on specific areas of interest, the system achieves high measurement precision without requiring a large scanning area, enabling portable operation in confined on-site environments.
3Device complexity
If manual inspection is performed for each cable joint, then the equipment requirement is minimal, but the inspection time and labor cost increase significantly
Solution Approach 1:
The patent replaces manual visual inspection with an automated laser scanning and image processing system. The laser scanner rapidly captures 3D surface data, and computer algorithms automatically analyze the geometry to detect defects, eliminating the need for manual inspection of each cable joint while significantly increasing inspection speed and productivity.
Solution Approach 2:
The system enables continuous inspection of cable ends by rapidly acquiring 3D surface data and immediately processing it for defect detection. This continuous automated inspection process eliminates the intermittent nature of manual inspection, maintaining high productivity throughout the cable joint installation process without requiring repeated setup or calibration.
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 provides a reliable, error-reduced method for assessing high voltage cable end quality, enabling precise defect detection and data storage for future reference, suitable for on-site use with a handheld 3D laser scanner.
Implementation Method 1
moving a non-contact surface scanner about the cable end such that the non-contact surface scanner measures distance to the surface over the area of the surface by sequentially measuring a plurality of sub-areas
Data Source
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AI summary
The invention relates to a system and a method for determining a quality of a surface of a high voltage cable end. The method comprising moving a non-contact surface scanner about the cable end, measuring distance to the surface over the area of the surface by sequentially measuring a plurality of sub-areas of the area of the surface, creating a continuous 3D surface geometry measurement of the surface of the cable end and comparing, using the continuous 3D surface geometry measurement with at least one surface geometry acceptance threshold determining the quality of the surface of the high voltage cable end.