Power Cable Joint Surface Inspection with 3D Laser Modeling
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Solution Overview
Problem
Conventional methods for inspecting the quality of processed layers in high voltage power cables rely heavily on human experience and are unreliable and non-replicable, lacking consistency in determining the quality of mechanical processing results.
Innovation Solution
An automated method using a laser scanner to generate 3D models of the outer surfaces of power cable layers, evaluating surface quality, and determining parameters such as angle, slope, roundness, and surface texture, with comparisons to reference models, to ensure consistent and reliable quality inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual inspection methods are used, then the inspection process is simple and requires minimal equipment, but the reliability and replicability of quality determination deteriorates due to dependence on human experience
Solution Approach 1:
The patent replaces manual tactile inspection with an automated optical measurement system using a laser scanner. The laser scanner captures 3D surface geometry data of the processed cable layers, eliminating the need for manual finger-based tactile feedback. This substitution of mechanical/manual inspection with optical automation directly resolves the contradiction by providing both equipment simplicity and improved reliability through objective, experience-independent measurements.
Solution Approach 2:
The patent creates a digital 3D copy of the processed surface geometry through laser scanning. Instead of relying on human tactile sensing, the system generates a precise digital representation of the surface that can be objectively analyzed against acceptance criteria. This copying approach enables reliable, replicable quality determination without depending on human experience while maintaining relatively simple inspection equipment.
2Reliability
If automated laser scanning is implemented, then the reliability and consistency of quality inspection is improved, but the device complexity and measurement system requirements increase
Solution Approach 1:
The patent employs a laser scanner to replace complex manual inspection procedures with automated optical measurement. While the measurement system becomes more technologically advanced, the overall device complexity is managed by using a focused laser scanning approach rather than comprehensive multi-sensor systems. The laser scanner provides reliable, consistent 3D surface geometry data that objectively determines quality without human experience variability.
Solution Approach 2:
The patent transitions from 2D visual or tactile inspection to 3D surface geometry measurement using laser scanning. By capturing depth information and creating three-dimensional models of the processed surfaces, the system achieves superior reliability and consistency in quality inspection. This dimensional enhancement allows for precise measurement of surface irregularities, slopes, and geometries that cannot be adequately assessed by traditional 2D methods.
3Device complexity
If conventional measurement tools like slide gauges are used, then the equipment remains simple and accessible, but the manufacturing precision and measurement accuracy of processed layers deteriorates
Solution Approach 1:
The patent replaces conventional mechanical measurement tools like slide gauges and diameter tapes with a laser scanning system. This substitution enables non-contact, high-precision 3D surface geometry measurement that accurately captures the true shape and dimensions of processed layers. The laser scanner provides manufacturing precision comparable to or exceeding contact-based mechanical tools while eliminating measurement uncertainties associated with manual tool usage.
Solution Approach 2:
The patent enhances measurement capability by transitioning from 1D or 2D measurements with conventional tools to comprehensive 3D surface geometry measurement. The laser scanner captures depth, curvature, slope, and surface profile information that single-dimensional mechanical measurements cannot detect. This dimensional advancement enables precise characterization of processed layer quality, including detection of subtle surface irregularities and accurate verification of geometric specifications.
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
Enables the construction of high-quality vulcanized joints by eliminating reliance on human experience, ensuring consistent and reliable inspection of the inner semiconducting layer and insulation thickness, thereby improving the quality of power cable joints.
Implementation Method 1
obtaining, from a laser scanner, measurements of an outer surface of an inner semiconducting layer
Implementation Method 2
measuring distance to the surface over the area of the surface by sequentially measuring a plurality of sub-areas
Data Source
AI summary
A method of performing a quality inspection of a vulcanized joint of a power cable during manufacturing of the vulcanized joint, the method comprising: a) obtaining, from a laser scanner, measurements of an outer surface of an inner semiconducting layer provided over a conductor joint which joints conductors of two power cable sections, and of a transition area between the outer surface and outer surfaces of a respective inner semiconducting layer of the two power cable sections, b) obtaining, from a laser scanner, measurements of an outer surface of a tapering section of an insulation layer arranged around a respective one of the inner semiconducting layers of the two cable sections, c) processing the measurements obtained in step a) and in step b), the processing involving generating one or a respective 3-d model of the outer surfaces and evaluating an outer surface quality of the outer surfaces based on the one or more 3-d models, d) presenting a conclusion regarding surface quality based on the evaluation, e) obtaining, from a laser scanner, measurements of an outer surface of a joint insulation arranged around the inner semiconducting layer that is provided over the conductor joint, the joint insulation having been provided over the inner semiconducting layer provided around the conductor joint after step d), and f) processing measurements obtained from the laser scanner in step e), the processing involving determining an insulation thickness or an outer diameter of the joint insulation, and g1) presenting the insulation thickness or outer diameter, and/or, g2) evaluating the insulation thickness or outer diameter, and presenting a conclusion regarding the insultation thickness or outer diameter based on the comparison.