Automated Optical Chain Inspection Using Camera and Guiding Means
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Solution Overview
Problem
Manual inspection of chains in industrial settings is prone to inaccuracies and inconsistencies, as it relies on visual evaluation and measurement of chain link lengths, which can miss individual link wear and lead to differing opinions among technicians, potentially resulting in unsafe conditions.
Innovation Solution
A method and arrangement using a camera with guiding means to position chains in front of the camera, allowing for the measurement of individual chain link characteristics such as gap, link length, and thickness, with reference edges for scale calibration, enabling accurate and reliable condition assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection by service technician is used, then inspection cost is low, but measurement precision and reliability deteriorate due to human error and inconsistency
Solution Approach 1:
The patent replaces the manual mechanical measurement system with an automated optical measurement system using a camera. The camera captures images of chain links, and image processing algorithms automatically measure link dimensions, eliminating human error and inconsistency while maintaining relatively simple device complexity.
Solution Approach 2:
The patent creates an optical copy (image) of the chain link and performs measurements on the digital copy rather than the physical object. This allows for precise, repeatable measurements without physical contact, improving measurement precision while keeping the device simple.
2Measurement precision
If visual inspection by hand is used, then inspection speed is fast, but measurement precision deteriorates due to inability to detect individual link wear
Solution Approach 1:
The patent divides the chain into individual link segments and inspects each link separately using image processing. This segmentation allows detection of wear in specific links that would be missed in visual inspection, while the automated process maintains high inspection speed by processing multiple links simultaneously through the camera system.
Solution Approach 2:
The patent introduces an intermediary image processing system between the camera and the final measurement result. This intermediary layer automatically analyzes chain link conditions, enabling precise detection of individual link wear while maintaining fast inspection speed through automated processing.
3Reliability
If measurement of eleven or more chain links is required, then reliability of overall chain assessment improves, but loss of time increases due to extensive measurement requirements
Solution Approach 1:
The patent implements continuous automated measurement of chain links through the camera system, eliminating the intermittent nature of manual measurement. The system can continuously capture and process images of multiple links, maintaining high reliability assessment while reducing total inspection time through uninterrupted automated operation.
Solution Approach 2:
The patent uses periodic image capture at regular intervals along the chain, allowing efficient measurement of multiple links. This periodic sampling approach maintains reliable chain condition assessment by measuring sufficient links while minimizing inspection time through systematic sampling rather than continuous manual measurement.
Data Source
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AI summary
There is provided a fast and a reliable way to inspect a condition of a chain (406) by an arrangement comprising a camera (402) and guiding means (404) for positioning a chain (406) in front of the camera (402) such that holes of consecutive chain links are visible to the camera. In a method for inspecting a chain (406) connected movable to a hoisting device, the chain (406) is positioned in front of the camera (402) by the guiding means (404) and the chain (406) is driven past the camera (402) by the hoisting device.