Detection System with Dual-Plane Positioning for Small Thickness Variations
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Solution Overview
Problem
Existing inspection systems fail to accurately locate and inspect specific features of objects with small thickness variations, particularly on both sides, due to manufacturing errors of ±1mm, necessitating precise positioning during nondestructive inspection.
Innovation Solution
An inspection system comprising a conveying mechanism, pushing mechanism, and positioning mechanism, which includes sensors and driving devices to accurately position an object on multiple planes for thorough inspection, ensuring precise alignment and measurement of features on both sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used, then the inspection process is simple, but the positioning accuracy of features with small thickness variations is insufficient
Solution Approach 1:
The inspection system is divided into multiple independent modules: conveying mechanism, pushing mechanism, positioning mechanism, and inspection mechanism. Each module performs a specific function, allowing the system to achieve high positioning accuracy through coordinated operation of segmented components rather than requiring a single complex system.
Solution Approach 2:
The pushing mechanism and positioning mechanism perform preliminary positioning actions before the inspection mechanism operates. The pushing mechanism pushes the object to be inspected to the first positioning plane and second positioning plane in advance, ensuring that the object is correctly positioned before inspection begins, thereby improving positioning accuracy without complicating the inspection process itself.
2Productivity
If the entire object is inspected, then no features are missed, but the inspection time and efficiency are reduced
Solution Approach 1:
The inspection system extracts and focuses on specific features of the object to be inspected rather than inspecting the entire object. The positioning mechanism positions the object such that only the relevant features are brought to the inspection plane, allowing the inspection mechanism to focus on these specific features. This extraction approach maintains inspection completeness for relevant features while significantly improving inspection efficiency.
Solution Approach 2:
The inspection system applies local quality by concentrating inspection resources on specific features of the object rather than uniformly inspecting the entire object. The positioning mechanism ensures that the features requiring inspection are precisely positioned at the inspection plane, allowing the inspection mechanism to apply concentrated detection effort where needed. This local quality approach maintains reliability for critical features while improving overall productivity.
3Reliability
If manual positioning is used, then the system complexity is low, but the positioning accuracy受 manufacturing errors affects inspection reliability
Solution Approach 1:
The positioning mechanism incorporates feedback control to compensate for manufacturing errors. The system uses sensors to detect the actual position of the object and adjusts the pushing mechanism accordingly to ensure accurate positioning. This feedback mechanism maintains high inspection reliability by automatically correcting positioning deviations caused by manufacturing tolerances, while the modular design keeps the overall system complexity manageable.
Solution Approach 2:
The system replaces manual positioning methods with an automated pushing mechanism that uses controlled mechanical force to position the object. The pushing mechanism, driven by a driving device, precisely pushes the object to the positioning plane, eliminating the need for manual positioning. This substitution improves reliability by removing human error while keeping complexity low through the use of simple, controlled mechanical action rather than complex automated positioning systems.
Data Source
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AI summary
An inspection system is provided, including: a conveying mechanism (10), a pushing mechanism (20), a positioning mechanism (30) and an inspection mechanism (40). The conveying mechanism (10) is configured to convey an object to be inspected (200). The pushing mechanism (20) is suitable for pushing the object to be inspected (200) in a conveying direction of the conveying mechanism (10), so as to push the object to be inspected (200) to a first positioning plane (M1) and a second positioning plane (M2). The positioning mechanism (30) includes a positioning portion (31). The positioning portion (31) may move in the conveying direction of the conveying mechanism (10), so as to define the first positioning plane (M1) and the second positioning plane (M2). The object to be inspected (200) abuts against the positioning portion (31) on the first positioning plane (M1) and the second positioning plane (M2). The inspection mechanism (40) is suitable for inspecting the object to be inspected (200) when the object to be inspected (200) is located on the first positioning plane (M1) and the second positioning plane (M2). An inspection method is further provided.