3D Scanned Factory Joint Inspection for Cable Layer Deviations
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Solution Overview
Problem
The manufacture of factory joints in high voltage cables is labor-intensive and requires skilled professionals for manual inspection, with prolonged feedback loops and unreliable quality control due to complex geometric designs and diverse surface irregularities.
Innovation Solution
A method using a 3D surface scanner to capture and merge layer-by-layer geometry and texture data, transforming it into a common reference system for thorough quality control, comparing parameters against tolerances, and outputting deviation signals for reworking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used with skilled professionals, then quality control can be performed, but the process is labor-intensive and has prolonged feedback loops
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical measurement system using a 3D surface scanner. The scanner captures geometric data of cable layers and joints, transforming physical inspection into digital analysis. This substitution eliminates the need for skilled manual inspection while providing rapid, objective quality control with immediate feedback, resolving the contradiction between reliability and productivity.
Solution Approach 2:
The patent creates a digital copy (3D surface model) of the physical cable joint and layers. This digital replica allows for rapid analysis, storage, and comparison without physically handling or repeatedly measuring the actual components. The copied geometric data can be processed instantly by software, providing immediate quality assessment and eliminating prolonged feedback loops while maintaining inspection accuracy.
2Ease of manufacture
If manual measurements are performed at strategically selected positions, then some quality attributes can be controlled, but comprehensive surface irregularity detection is unreliable
Solution Approach 1:
The patent transitions from point-based manual measurements to comprehensive 3D surface scanning. Instead of measuring at discrete strategic positions, the 3D scanner captures the entire surface geometry of cable layers and joints, including all surface irregularities, deviations, and defects. This dimensional expansion from 0D point measurements to 3D surface mapping ensures complete coverage and reliable detection of all surface anomalies while maintaining ease of operation through automated scanning.
3Device complexity
If electrical quality control is performed only after insulation layer completion, then feedback is simplified, but the feedback loop is prolonged
Solution Approach 1:
The patent performs geometric quality control of cable layers and joints immediately after each layer is applied, before proceeding to the next layer or completing electrical testing. The 3D surface scanner inspects each layer's geometry, detects deviations, and provides feedback while the work is still fresh and easily correctable. This preliminary inspection prevents defects from propagating through subsequent layers, significantly reducing rework time and eliminating prolonged feedback loops without increasing overall process complexity.
Data Source
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AI summary
A method (46) for manufacturing and inspecting a factory joint during installation comprises the steps of: a) preparing (48) an initial layer of the factory joint, b) capturing (50) and storing (52) 3D data of an outer surface of the initial layer by using a 3D surface scanner, c) preparing (48) a subsequent layer, d) capturing and storing 3D data of an outer surface of the subsequent layer, e) merging (54) the 3D data by transformation into a common reference system, f) analyzing (56) the resulting merged 3D model to determine shape parameters and/or surface texture parameters, g) comparing (58) the determined parameters with expected parameters, and if the determined parameters deviate by more than a predetermined tolerance from the expected parameters outputting (62) a deviation signal, and h) repeating steps c) to g) until the factory joint is completed.