Coaxial Detection Tool Using Photosensitive Plate and Optical Imaging
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Solution Overview
Problem
Conventional coaxial relationship detection methods are inefficient and prone to positioning errors due to the need for multiple reference changes and specialized detection pin shafts for different hole diameters, making them unsuitable for precise and rapid assessment, especially for small holes.
Innovation Solution
A detection tool utilizing a photosensitive material and a light-shielding box with conveyor belts, cameras, and image processing to automatically and accurately determine the coaxiality of two holes by forming circular patterns on a photosensitive plate and calculating their centers, allowing for rapid and precise detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional dial gauge and detection pin shaft method is used, then the coaxial relationship can be detected, but the detection efficiency is low and positioning errors are large due to multiple reference changes
Solution Approach 1:
The patent replaces the mechanical dial gauge and detection pin shaft system with an optical detection system. Light sources illuminate the workpiece, and cameras capture images of the holes. Image processing algorithms automatically calculate coaxiality, eliminating manual mechanical measurement operations and achieving both high precision and high efficiency.
Solution Approach 2:
The patent creates optical copies (images) of the workpiece holes using cameras. Instead of physically contacting the holes with detection pin shafts, the system captures digital images and processes them computationally to determine coaxial relationships, enabling rapid and precise measurement without physical reference changes.
2Adaptability or versatility
If specialized detection pin shafts are fabricated for different hole diameters, then accurate detection can be achieved, but the device complexity increases and the scope of application is limited
Solution Approach 1:
The patent creates a universal detection system that can handle various hole diameters and workpiece types using the same apparatus. The optical system with cameras and image processing algorithms automatically adapts to different geometries without requiring specialized detection tools, greatly expanding the scope of application while maintaining simplicity.
Solution Approach 2:
The patent changes the detection approach from physical contact with diameter-matched pin shafts to optical imaging where parameters like hole diameter do not constrain the system. The camera system captures images and software algorithms process varying dimensions, allowing the same device to detect coaxiality across different hole sizes without physical reconfiguration.
3Measurement precision
If manual operation and reading by a measuring person is used, then the detection can be performed, but the efficiency is low and measurement errors are large
Solution Approach 1:
The patent implements an automated system where the detection apparatus performs measurement and calculation independently without human intervention. Cameras automatically capture images, image processing algorithms automatically calculate hole centers and coaxiality, and results are generated automatically, eliminating manual operation, reading, and calculation steps that cause time loss and human error.
Solution Approach 2:
The patent incorporates automatic feedback through image processing and computational analysis. The system captures images, processes them through algorithms that calculate hole centers and coaxial deviations, and provides immediate automated results. This closed-loop automated measurement process eliminates manual reading errors and significantly reduces detection time compared to human-operated systems.
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 tool significantly improves detection efficiency and precision, automates the process, and reduces operator errors, making it applicable to various workpieces with a wide range of hole diameters and enhancing the quality control of precision parts.
Implementation Method 1
a photosensitive plate is fixedly and circumferentially connected right in a middle of an outer surface of the second conveyor belt... the photosensitive plate extends rightward to a position right in a middle of an opening of the U-shape and covers the two axial holes
Data Source
AI summary
A rapid detection tool for a coaxial relationship based on a photosensitive material and a detection method using the same are used to detect coaxiality of two through-holes in the same workpiece to be detected. An image processing unit and a control unit are mounted outside a light-shielding box. Light sources, cameras, sensors, and an air cylinder are mounted in the light-shielding box. A photosensitive plate coated with a photosensitive resin is placed between the two holes, and two sides are irradiated by the light sources. Coordinates of centers of circular patterns formed on the photosensitive plate are calculated so that a coaxial relationship between the two holes can be accurately obtained. An output rod of the air cylinder is controlled to extend outward to reject a workpiece to be detected not meeting requirements.