Flange Sealing Surface State Determination via Image Color Analysis
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Solution Overview
Problem
The existing gas leak detection systems require technical knowledge and expertise to assess the state of sealing surfaces on flanges, making it difficult for non-experts to determine the necessary repairs, such as rust or adhesive material issues, which can lead to improper maintenance.
Innovation Solution
A determination system that includes an image acquisition unit, color difference calculation, coincidence calculation, and determination units to assess the state of the sealing surface based on image analysis, providing advice on necessary actions like polishing or cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection of sealing surface is performed by worker, then maintenance operation can be performed, but technical knowledge and experience are required making it difficult for non-experts
Solution Approach 1:
The patent replaces the manual visual inspection mechanism with an automated image processing system. A camera captures images of the sealing surface, and computer processing automatically analyzes rust adhesion and adhesive material presence, eliminating the need for expert visual assessment while maintaining high accuracy through objective image analysis
Solution Approach 2:
The patent creates a digital copy of the sealing surface through image capture. Instead of relying on expert visual interpretation of the physical surface, the system analyzes a replicated digital representation, allowing non-experts to perform inspections with the same effectiveness as experts by comparing image data against predetermined standards
2Measurement precision
If expert performs sealing surface inspection, then accurate determination can be made, but time is required for expert assessment
Solution Approach 1:
The patent enables continuous automated inspection through image capture and processing. Multiple images can be captured and analyzed in rapid succession without the breaks or fatigue limitations of human experts, maintaining high measurement precision while significantly reducing inspection time through uninterrupted automated operation
Solution Approach 2:
The system performs self-assessment of the sealing surface state through automated image analysis. The computer processing unit independently evaluates rust adhesion and adhesive material presence without requiring expert intervention, achieving both high accuracy and speed through autonomous operation
3Loss of time
If non-expert performs sealing surface inspection, then time is saved, but accurate determination cannot be made
Solution Approach 1:
The patent substitutes the human inspection mechanism with an automated system that combines image capture with computer-based image processing. This replacement allows non-experts to achieve expert-level accuracy because the system objectively analyzes image data against predetermined standards for rust adhesion and adhesive material detection, eliminating the skill gap while maintaining speed
Data Source
AI summary
A system includes: an acquisition unit that acquires an image of a sealing surface of a flange; a calculation unit that calculates a first color difference between a color value of a first image of a first sealing surface to which rust is adhered and a color value of the image and a second color difference between a color value of a second image of a second sealing surface on which an adhesive material does not exist and a color value of the image; a coincidence calculation unit that calculates first coincidence between the first sealing surface and the sealing surface based on the first color difference, and calculates second coincidence between the second sealing surface and the sealing surface based on the second color difference; and a determination unit that determines a state of the adhesive material on the sealing surface based on the first and second coincidence.