Fastener Deflection Measurement Using Dual-Axis Optical Sensing
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Solution Overview
Problem
Existing methods for determining the deflection of fasteners, such as screws, are not suitable for moving components during material flow, as they require fixed connections and are not effective in measuring deflection in multiple planes, leading to assembly issues due to thermal treatment and multilayer arrangements in furnaces.
Innovation Solution
A method and apparatus using two cameras with perpendicular optical axes to record images of the fastener, determining reference points and inspection points to calculate deflection in three dimensions, allowing for deflection measurement during movement and assembly without external loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fastener is thermally treated in a continuous strip furnace with multilayer arrangement, then throughput and production efficiency are improved, but deflection and bending of the fastener increase due to weight and heat
Solution Approach 1:
The patent measures deflection during the thermal treatment process itself, before the fastener completes its journey through the furnace. By using optical sensors to detect deflection in real-time during material flow, the system can identify problematic fasteners early and sort them out before assembly, preventing quality issues without requiring additional post-treatment inspection steps
Solution Approach 2:
The patent replaces mechanical contact-based measurement methods with optical sensing. Instead of physically touching or supporting the fastener on two points as in conventional methods, the system uses light-based sensors to non-contactly detect deflection, enabling measurement of moving components during material flow without disrupting the thermal treatment process
2Ease of operation
If conventional deflection measurement methods are used with fixed connections and single-plane sensors, then measurement simplicity is maintained, but they cannot measure moving components during material flow and cannot detect deflection in multiple planes
Solution Approach 1:
The patent transitions from single-plane deflection measurement to three-dimensional deflection detection by introducing multiple optical sensors positioned at different angles and locations. This multi-plane measurement capability allows the system to capture deflection in both transverse directions and along the longitudinal axis, providing comprehensive quality assessment of fasteners during material flow
Solution Approach 2:
The patent creates a universal measurement system that can handle moving components during material flow, unlike conventional methods requiring fixed connections. The optical sensing approach with multiple detectors can measure deflection of various fastener types and sizes in a single integrated system, accommodating different production scenarios without requiring method changes
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
Enables effective and cost-efficient deflection measurement of fasteners in two perpendicular planes, allowing for high-throughput analysis during material flow and automatic sorting based on deflection tolerance, improving assembly precision and reducing material defects.
Implementation Method 1
recording a first image of the fastener with a first camera having an optical axis
Data Source
AI summary
A method and an apparatus serve for determining the deflection of a fastener, especially a screw. The method includes the steps of (a) recording a first image of the fastener with a first camera; (b) determining two first reference points of the fastener in the first image for determining a first reference axis of the fastener, the first reference axis extending through the two first reference points; (c) determining a first inspection point in a first inspection region in the first image; (d) comparing the position of the first inspection point with the respective position of the first reference axis for determining a first deviation; (e) recording a second image of the fastener with a second camera, the optical axis of the second camera being substantially perpendicular to the optical axis of the first camera, the optical axes of the first and second camera approximately intersecting in the longitudinal axis of the fastener; (f) determining two second reference points of the fastener in the second image for determining a second reference axis of the fastener, the second reference axis extending through the two second reference points; (g) determining a second reference point in a second inspection region in the second image; and (h) comparing the position of the second inspection point with the respective position of the second reference axis for determining a second deviation.