Ceramic Honeycomb Inspection Alignment via Hill Climb
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Solution Overview
Problem
Existing automated inspection systems for ceramic honeycomb bodies face challenges in repeatable alignment and defect detection due to variations in part orientation, leading to inconsistent image analysis and poor repeatability.
Innovation Solution
An automated inspection apparatus and method that aligns the ceramic honeycomb body with the optical axis using a diffuse light source and telecentric lens, employing a hill climb method to determine yaw and pitch alignment, ensuring accurate and repeatable imaging of internal defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated inspection systems are used for ceramic honeycomb bodies, then inspection efficiency is improved, but repeatability and accuracy deteriorate due to variations in part orientation
Solution Approach 1:
The system performs preliminary alignment of the ceramic honeycomb body with the optical axis before inspection using a hill climb method. The part orientation is adjusted in advance to maximize light transmission through the channels, ensuring consistent imaging conditions. This preliminary orientation step resolves the repeatability issue by establishing a standardized reference frame before the actual inspection process begins.
2Speed
If automated inspection systems are used for ceramic honeycomb bodies, then inspection speed is improved, but measurement precision deteriorates due to inconsistent part alignment
Solution Approach 1:
The system employs a feedback mechanism where the camera captures images of the honeycomb body, and the controller analyzes the light transmission pattern to determine part orientation. Based on this feedback, the system automatically adjusts the part orientation to align with the optical axis. This closed-loop feedback ensures high measurement precision while maintaining automated inspection speed.
3Device complexity
If simple alignment methods are used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to achieve accurate channel alignment
Solution Approach 1:
The system uses the honeycomb body's own structure (its channels) to perform self-alignment. Light is transmitted through the channels, and the pattern of light transmission provides automatic feedback about the part's orientation. The system leverages the part's inherent geometry rather than requiring complex external alignment fixtures, achieving high alignment accuracy with relatively simple equipment.
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
The solution provides repeatable and accurate detection of internal defects such as cracks, tears, and dead channels, improving inspection repeatability and accuracy compared to manual methods, while allowing for efficient inspection of large ceramic honeycomb structures with non-parallel channels.
Implementation Method 1
A diffuse light source transmits light through a ceramic honeycomb body having axially extending channels
Implementation Method 2
A telecentric lens produces a magnified image of the part
Data Source
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AI summary
An inspection apparatus and method to automatically inspect ceramic honeycomb bodies during the manufacturing thereof. The apparatus includes a light source to shine light through channels of the ceramic honeycomb body, a lens to receive at least a portion of the light transmitted through channels of the ceramic honeycomb body, a camera to capture images of the transmitted light, a support chuck to support the honeycomb body, and a controller to receive the captured images, to analyze each captured image, to adjust the support chuck and/or the lens based on the analysis, and to align the ceramic honeycomb body channels and the lens optical axis.