3D Cable Surface Scanning for Quality Control
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Solution Overview
Problem
Current quality control methods for high voltage and medium voltage cables are inefficient, relying on human inspection and electrical testing, which are time-consuming and lack accuracy, particularly in assessing defects in semiconductive and insulative layers, and fail to provide real-time feedback for manufacturing improvements.
Innovation Solution
A method utilizing 3D surface scanning to capture and process geometry data, identifying anomalies, and generating quality reports, which includes interpolation for incomplete data, finite element simulations for fault prediction, and machine learning for improved defect detection, enabling rapid and accurate quality assessment and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D surface scanning is used to inspect cable surfaces, then measurement precision and manufacturing precision are improved, but device complexity and processing time increase due to large amounts of data
Solution Approach 1:
The patent divides the cable surface inspection into multiple sub-areas that are scanned sequentially. The large 3D surface is segmented into manageable portions, each processed independently, then combined to form the complete quality assessment. This reduces the complexity of processing any single data set while maintaining comprehensive coverage.
Solution Approach 2:
The patent extracts and processes only the critical geometric features and anomalies from the large 3D scan data, rather than processing the entire surface uniformly. By identifying and focusing on defect-prone areas and significant geometric deviations, the system reduces processing requirements while maintaining high measurement precision for quality control.
2Device complexity
If human eye inspection is used for quality control, then device complexity is reduced, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces human visual inspection with an automated 3D surface scanning system that uses optical or laser measurement techniques. This substitution provides consistent, repeatable measurements free from human error, fatigue, or subjective judgment, while the systematic approach to data processing keeps the overall device complexity manageable through algorithmic automation.
3Reliability
If electrical testing methods are used for quality control, then reliability is improved through electrical strength assessment, but measurement precision for geometric defects deteriorates
Solution Approach 1:
The patent creates a multi-functional quality control system that combines 3D surface geometry scanning with electrical testing capabilities. The same inspection system can assess both geometric defects (surface quality, dimensional accuracy) and electrical properties (through integration with electrical testing equipment), providing comprehensive quality assurance without requiring separate specialized systems for each type of inspection.
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 enhances processing efficiency, increases accuracy, and provides immediate feedback for manufacturing improvements, reducing scrap rates and enabling real-time tracking of component dimensions, thereby optimizing production processes and reducing costs.
Implementation Method 1
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
Data Source
AI summary
A method is provided for determining a quality of a surface of a cable, a part of a cable or an accessory for a cable. The method includes capturing and storing a set of 3-dimensional (3D) surface geometry measurement data of an area of interest of a surface of the cable or cable component by moving a 3D surface scanner about the cable over the area of interest. In an analysis unit, a continuous 3D surface geometry measurement is created of the area of interest by processing measurement data from the 3D surface scanner. The processing includes identifying anomalies in the continuous 3D surface geometry and inspect the captured 3D surface geometry measurement data to discover sub-areas with increased probability for faults. A quality report for the scanned surface is provided.