Automated Flake Thickness Measurement Using 3D Laser Imaging
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Solution Overview
Problem
Existing oilseed crush operations face challenges in efficiently collecting and measuring the thickness of oilseed flakes, which affects oil yield and requires manual labor for frequent sampling and measurement.
Innovation Solution
An automated system and method for collecting and measuring the thickness of oilseed flakes using a sampling system and an imaging system with 3D laser displacement, enabling precise flake thickness data capture and automatic adjustment of flake rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sampling and measurement methods are used, then device complexity is reduced, but measurement precision and productivity deteriorate
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated imaging system that uses optical capture and 3D laser displacement technology to measure flake thickness. This substitution eliminates manual labor while achieving precise measurements through digital image processing and automated analysis algorithms.
Solution Approach 2:
The imaging system creates digital copies (images) of the flakes for measurement purposes. By capturing optical images and generating 3D surface maps, the system measures flake thickness from digital representations rather than requiring direct physical contact or manual measurement, thereby improving precision without proportionally increasing system complexity.
2Measurement precision
If frequent sampling is performed, then measurement precision improves, but loss of time increases
Solution Approach 1:
The automated system enables continuous or near-continuous sampling and measurement operations without the time losses associated with manual method transitions. The imaging system can rapidly capture multiple samples sequentially, maintaining continuous measurement capability and eliminating idle time between sampling events.
Solution Approach 2:
The system performs self-service through automated image capture, processing, and analysis. The imaging system automatically measures flake thickness from captured images without requiring operator intervention for each measurement, thereby enabling frequent sampling without proportional increases in time loss.
3Measurement precision
If automated imaging system with 3D laser displacement is used, then measurement precision improves, but use of energy increases
Solution Approach 1:
The system optimizes energy consumption by adjusting operational parameters of the imaging system, such as laser power levels and camera exposure settings, to achieve sufficient measurement precision with minimal energy input. The 3D laser displacement technology uses controlled energy levels appropriate for the specific measurement requirements of flake thickness.
4Manufacturing precision
If automated flake roller adjustment is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system implements feedback control where measurement data from the imaging system is used to automatically adjust flake roller settings. The measured flake thickness values feed back to the control system, which then modifies roller position or pressure to maintain desired thickness specifications, achieving consistent manufacturing precision through closed-loop control.
Solution Approach 2:
The automated control system serves multiple functions: it processes measurement data, determines compliance with specifications, adjusts roller settings, and maintains overall process control. By consolidating these functions into a single multi-functional system, the patent manages device complexity while achieving improved manufacturing precision.
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 automated system optimizes oil yield by maintaining desired flake thickness, reduces manual labor, facilitates more frequent and accurate sampling, and allows for analysis of flake roller wear for maintenance optimization.
Implementation Method 1
an imaging system with 3D laser displacement, enabling precise flake thickness data capture
Data Source
AI summary
A flake measurement system of an oilseed crush operation includes a sampling system to collect an oilseed flake from the oilseed crush operation and place the oilseed flake on a supporting surface, and an imaging system to determine a thickness of the oilseed flake, with the imaging system including an imaging device to capture an image of a surface of the oilseed flake, the imaging system to process the image to identify a local minima region of the surface of the oilseed flake, and the imaging system to determine the thickness of the oilseed flake based on displacement of the local minima region relative to the supporting surface.