Ceramic Honeycomb Alignment via Telecentric Optical Inspection
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Solution Overview
Problem
Existing methods for inspecting ceramic honeycomb bodies lack repeatability and accuracy due to poor alignment with the optical axis, particularly in detecting defective plugs, which affects the reliability of light leaker identification in filters.
Innovation Solution
An automated system using a telecentric lens and diffuse backlight for aligning ceramic honeycomb bodies with the optical axis, allowing for precise detection and measurement of light leakers by calculating the angular displacement necessary to achieve alignment, and utilizing image processing to identify and record defective plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment methods are used for ceramic honeycomb bodies, then the inspection process is simple, but the alignment accuracy and repeatability are poor
Solution Approach 1:
The system uses the honeycomb body's own geometric features (cell walls, plugs) as alignment references. The automated alignment algorithm processes images of the honeycomb body to automatically determine its orientation and position relative to the optical axis, making the object itself serve as the alignment standard rather than requiring external fixtures or manual intervention.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated optical-mechanical system. A telecentric lens captures images of the honeycomb body, and a controller automatically processes these images to calculate alignment parameters and adjust the body's position, substituting human operators and manual tools with an automated vision-based system.
2Reliability
If automated alignment systems are implemented, then alignment accuracy and repeatability improve, but the device complexity increases
Solution Approach 1:
The alignment system serves multiple functions: it captures images of the honeycomb body, automatically determines alignment parameters, calculates angular displacement, and controls positioning adjustments. This multi-functional integrated system replaces what would otherwise require separate devices for imaging, measurement, calculation, and positioning control, reducing overall system complexity while maintaining high reliability.
Solution Approach 2:
The system uses telecentric lens imaging to capture geometric parameters of the honeycomb body under controlled lighting conditions. By changing the imaging parameters (using telecentric optics with specific numerical aperture and magnification), the system achieves consistent, repeatable measurements that are insensitive to small variations in object distance, thereby improving reliability without proportionally increasing complexity.
3Measurement precision
If telecentric lens with diffuse backlight is used, then detection precision of light leakers improves, but the manufacturing cost increases
Solution Approach 1:
The diffuse backlight serves as an intermediary element that transforms direct light into scattered illumination, creating uniform lighting across the honeycomb body's surface. This intermediary lighting approach eliminates harsh shadows and hot spots, enabling the telecentric lens to capture consistent images of light leakers without requiring complex lighting control mechanisms, thereby improving detection precision while keeping the lighting system simple and cost-effective.
4Productivity
If automated inspection is implemented, then productivity and consistency improve, but the initial equipment investment increases
Solution Approach 1:
The automated system enables continuous inspection of ceramic honeycomb bodies by maintaining constant telecentric imaging and automated image processing. The system can continuously capture images, analyze alignment parameters, detect light leakers, and record results without interruption, eliminating the stop-start nature of manual inspection and achieving sustained high productivity through uninterrupted automated operation.
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 system achieves improved repeatability and accuracy in inspecting ceramic honeycomb bodies by ensuring consistent alignment, enabling effective detection and assessment of light leakers, including translucent plugs, and can be implemented inline on a production line without additional equipment.
Implementation Method 1
directing light toward a first end of a ceramic honeycomb body... capturing a plurality of images of the second end
Implementation Method 2
diffuse backlight for aligning ceramic honeycomb bodies with the optical axis, allowing for precise detection and measurement of light leakers
Data Source
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AI summary
An apparatus and method to align ceramic honeycomb bodies. The apparatus includes a light source to direct light toward a first end of a ceramic honeycomb body, a lens to receive at least a portion of the light directed to the first end of the ceramic honeycomb body, an imaging device to capture an image of the received light, wherein the image comprises a portion of a side surface of the honeycomb body. The apparatus comprises a controller configured to receive the captured image, to analyze the captured image based on the portion of the side surface, to adjust the ceramic honeycomb body and/or the lens based on the analysis to align the ceramic honeycomb body and the lens optical axis.