Cable Surface Scanner With 3D Defect Detection Mapping
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Solution Overview
Problem
Existing X-ray systems used in power cable manufacturing are complex and unable to provide detailed information on the quality of the extruded surface, necessitating a device for continuous monitoring and automatic detection of surface defects in cables.
Innovation Solution
A surface scanner comprising non-contact distance measurement sensors, such as laser displacement sensors, and a processor that creates a continuous 3D topographic map of the cable's outer surface, utilizing a neural network for defect detection, allowing for real-time monitoring and automatic defect identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If X-ray systems are used to measure layer depths and conductor eccentricity, then internal cable structure measurement is improved, but device complexity increases and surface defect detection capability deteriorates
Solution Approach 1:
The patent extracts the surface measurement function from the complex internal measurement system by introducing a separate laser-based surface scanner. This scanner uses non-contact distance measurement sensors to specifically detect surface defects while the X-ray system handles internal structure measurement, thereby reducing the complexity burden on any single system and improving overall measurement capability.
Solution Approach 2:
The measurement system is segmented into two independent components: an X-ray system for internal structure measurement and a laser-based surface scanner for surface defect detection. This segmentation allows each subsystem to be optimized for its specific function without the complexity overhead of a monolithic system, resolving the contradiction between measurement precision and device complexity.
2Loss of information
If X-ray systems are used for internal cable measurement, then averaged layer depth information is obtained, but surface quality detail information is lost
Solution Approach 1:
The patent replaces contact-based or averaged measurement methods with non-contact laser distance measurement sensors that utilize optical triangulation principles. This substitution enables high-resolution surface topography mapping without physical contact, preserving detailed surface quality information that would otherwise be lost in averaged measurements.
Solution Approach 2:
The surface scanner creates three-dimensional topographic maps of the cable surface by measuring distance variations in multiple points across the surface. This dimensional approach (creating 3D surface profiles) provides detailed surface quality information that cannot be obtained from traditional two-dimensional averaged measurements, thereby recovering lost surface detail information.
3Productivity
If continuous surface monitoring is implemented, then surface defect detection capability is improved, but device complexity increases
Solution Approach 1:
The surface scanner is designed to continuously scan the cable surface during production by maintaining constant laser beam traversal across the moving cable. The non-contact distance measurement sensors continuously measure surface topography as the cable passes through, enabling uninterrupted real-time surface defect detection without stopping production, thereby improving productivity.
Solution Approach 2:
The system uses the cable's own motion through the scanner to enable continuous scanning without requiring complex mechanical scanning mechanisms. The cable's movement through the fixed laser sensor array automatically provides the scanning action, simplifying the device structure while maintaining continuous monitoring capability.
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 continuous and accurate monitoring of the extruded surface quality, detecting defects such as scorch marks, bumps, and dents, improving the reliability of power cables by providing detailed geometry and quality metrics, and integrating seamlessly with existing X-ray systems in cable manufacturing lines.
Implementation Method 1
the sensors being arranged to calculate the distance to the outer surface of the cable by focusing light reflected from the outer surface of the cable on the receiver which comprises a light-receiving element
Implementation Method 2
the sensors comprising laser displacement sensors being arranged to the support part
Data Source
AI summary
A surface scanner for surface defect detection of a cable comprises a measuring part and an analysis part, the measuring part comprises non-contact distance measurement sensors, the cable is positionable between the sensors such that beams of the sensors are directable to the outer surface of the cable to sample areas at a circumference of the cable for a length of the outer surface (L) of the cable in a run direction (x) of the cable for providing measurement data, and the analysis part comprises a receiver for the measurement data, a processor for processing the measurement data providing defect detection data and a continuous 3D topographic map of the outer surface of the cable, the analysis part comprising a neural network trained for detecting surface defects of the cable and outputting surface defects detection data. The invention also relates to an arrangement and a method for surface defect detection of a cable.