3D Surface Scanning for High-Voltage Cable Smoothness Control
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Solution Overview
Problem
Current quality control methods for high voltage and medium voltage cable components, such as electrodes and insulators, are inadequate for ensuring precise surface finish and geometry, leading to potential electrical failures due to surface irregularities and wear, with existing inspection techniques being costly, time-consuming, and lacking accuracy.
Innovation Solution
A method and system using non-contact 3D surface scanners and optical profilometers to capture and analyze surface geometry data, employing post-processing algorithms to detect irregularities and generate quality reports, and utilizing 3D marker fixtures to avoid data loss, ensuring accurate inspection without talc spray or surface markers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional 2D mechanical stylus roughness measurements are used, then the inspection process is simple and cost-effective, but the measurement accuracy and resolution are insufficient to detect surface irregularities that cause electrical failures
Solution Approach 1:
The patent replaces mechanical stylus measurement systems with optical measurement systems (optical profilometry and 3D surface scanning). This substitution eliminates the mechanical contact method that limited measurement resolution while providing sufficient accuracy to detect surface irregularities that cause electrical failures, without significantly increasing overall system complexity.
Solution Approach 2:
The patent creates digital 3D copies of surface geometries through optical scanning and profilometry. These digital representations allow for precise measurement and analysis of surface irregularities without physical contact, enabling high measurement accuracy while maintaining operational simplicity through automated data processing.
2Measurement precision
If optical profilometry and 3D surface scanning are used to achieve high measurement accuracy, then surface irregularities can be detected with sufficient precision, but the inspection process becomes more complex and time-consuming
Solution Approach 1:
The patent performs preliminary surface preparation and positioning actions, such as applying talc spray or using 3D markers on the surface before scanning. This preliminary action ensures optimal scanning conditions and data quality, enabling faster and more accurate inspection by preventing measurement errors that would require re-inspection.
Solution Approach 2:
The patent implements automated feedback mechanisms where the scanned 3D surface geometry data is immediately processed and compared against specification criteria. The system provides real-time feedback on pass/fail status, allowing for rapid decision-making and reducing overall inspection time by eliminating manual review delays.
3Measurement precision
If 3D markers and talc spray are applied to the surface during scanning to improve measurement accuracy, then surface reflection and positioning are improved, but the surface may be contaminated or marked
Solution Approach 1:
The patent extracts and removes the harmful elements (talc spray and permanent 3D markers) from the inspection process by implementing alternative solutions such as phase-shifted fringe projection optical profilometry and laser scanning without surface markers. This eliminates surface contamination while maintaining measurement precision through non-contact optical methods.
Solution Approach 2:
The patent converts the potential harm of surface contamination into a benefit by using the scanned surface geometry data itself as a reference for positioning and measurement. The 3D surface map obtained from scanning serves dual purposes: it provides the measurement data and acts as the positioning reference, eliminating the need for separate markers and talc spray.
4Productivity
If manual visual inspection is used, then the inspection process is simple and quick, but it is not fool-proof and lacks consistent accuracy
Solution Approach 1:
The patent implements self-service inspection through automated optical scanning and computer-aided evaluation systems that objectively assess surface quality without human intervention. The system automatically compares scanned geometries against digital specifications and provides consistent pass/fail determinations, eliminating the variability and subjectivity of manual visual inspection while maintaining high productivity.
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 fast, accurate, and cost-effective quality control by detecting surface irregularities and wear, enhancing electrical performance and durability of cable components through precise surface inspection and digital documentation.
Implementation Method 1
capture and store a set of 3-dimensional, 3D, surface geometry measurement data of an area of interest of a surface of the cable component by moving a 3D surface scanner over the area of interest
Implementation Method 2
optical profilometry provides more accurate, higher resolution results in three dimensions
Data Source
AI summary
A method and a system is provided for inspecting surfaces and/or interfaces of high voltage and/or medium voltage cable components. 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. The captured 3D surface geometry measurement data are inspected to determine smoothness of the scanned surface, and the smoothness is compared with threshold data to provide a quality report for the scanned surface.