Factory Joint 3D Layer Inspection for Cable Geometry Control
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Solution Overview
Problem
The manual labor-intensive process of manufacturing factory joints in high voltage cables lacks a reliable and thorough quality control, particularly in the inspection of geometric designs and surface irregularities, leading to potential electrical failures due to dielectric breakdowns.
Innovation Solution
A method using a 3D surface scanner to capture and merge layer-by-layer geometry and texture data into a common reference system, comparing parameters with tolerances, and outputting deviation signals for reworking, ensuring accurate and documented quality control of factory joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used for factory joint quality control, then the process is simple and requires basic equipment, but the measurement precision and detection reliability are insufficient
Solution Approach 1:
The patent replaces manual mechanical inspection methods with a 3D surface scanning system that captures geometric and texture data digitally. This substitution enables precise measurement of surface irregularities, layer thicknesses, and geometric parameters without relying on manual measurements, directly improving inspection precision while the automated processing handles the complexity.
Solution Approach 2:
The patent creates a digital 3D copy of the factory joint's surface geometry and texture characteristics through scanning. This digital replica allows for repeated analysis, comparison with reference models, and precise measurement without physically touching or disturbing the actual joint, thereby improving measurement precision while the digital nature handles complexity efficiently.
2Reliability
If comprehensive quality control inspection is performed on all layers, then the reliability of factory joint is improved, but the inspection time and productivity are reduced
Solution Approach 1:
The patent enables continuous scanning and inspection of multiple layers without interrupting the manufacturing flow. The 3D surface scanner can continuously capture data from each layer as it is applied, and the automated processing system continuously analyzes the data, maintaining uninterrupted inspection across all layers while improving reliability through comprehensive coverage.
Solution Approach 2:
The patent performs inspection activities during the manufacturing process itself rather than as a separate post-processing step. By scanning and analyzing each layer immediately after application, the system ensures quality control is built into the manufacturing flow, improving reliability while maintaining productivity through integrated rather than sequential operations.
3Manufacturing precision
If detailed geometric and surface texture parameters are measured, then the manufacturing precision is improved, but the complexity of data processing and analysis increases
Solution Approach 1:
The patent replaces complex manual measurement and analysis processes with automated 3D scanning and digital image processing algorithms. The system automatically extracts geometric parameters (layer thicknesses, surface profiles) and texture parameters from scanned data, achieving high manufacturing precision while the automated software handles the computational complexity.
Solution Approach 2:
The patent creates detailed digital copies of surface geometry and texture that can be analyzed repeatedly without additional measurement complexity. Once the 3D scan is acquired, the digital model allows for extraction of multiple parameters (thickness, profile, roughness) from the same data set, improving manufacturing precision assessment while avoiding repeated complex measurement procedures.
4Productivity
If feedback loop between manufacturing and quality control is shortened, then the productivity is improved, but the complexity of integrating inspection into manufacturing process increases
Solution Approach 1:
The patent merges the quality control inspection function directly into the manufacturing process by positioning the 3D surface scanner to inspect layers during or immediately after application. The scanning system is integrated with the manufacturing workflow so that inspection occurs in-line rather than as a separate post-processing step, improving productivity through continuous flow while the integrated design manages the complexity of coordination.
Solution Approach 2:
The patent implements real-time feedback by analyzing scanned data immediately after each layer is applied and providing results back to the manufacturing process without delay. This allows for immediate detection of defects and adjustments during manufacturing, improving productivity by eliminating long feedback loops while the automated real-time processing system handles the complexity of immediate analysis and response.
Data Source
AI summary
A method (46) for manufacturing and inspecting a factory joint during installation includes preparing (48) an initial layer of the factory joint, capturing (50) and storing (52) 3D data of an outer surface of the initial layer by using a 3D surface scanner, and preparing (48) a subsequent layer. 3D data of an outer surface of the subsequent layer is captured and stored. The 3D data is merged by transformation into a common reference system, and the resulting merged 3D model is analyzed to determine shape parameters and/or surface texture parameters. The determined parameters are compared with expected parameters, and if the determined parameters deviate by more than a predetermined tolerance from the expected parameters, a deviation signal is output. The third through eight steps may be repeated until the factory joint is completed.