Forging Workpiece Elongation Measurement via Image Processing
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Solution Overview
Problem
Existing methods for measuring the elongation of forging workpieces during forging operations are inefficient and prone to errors, particularly in daily operations, due to the difficulty in accessing both ends of the workpiece and the time-consuming and dangerous process of connecting/disconnecting steel cables, and the limitations of visual or laser scanning methods.
Innovation Solution
A method and system utilizing image processing to determine the elongation and vertical displacement of workpieces by acquiring and processing multiple images of marked patterns on the workpiece surface before and after a forging blow, allowing for contactless and accurate measurement of elongation and displacement in standard units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If steel cables are connected to measure workpiece length, then measurement can be performed, but it takes too much time and is dangerous
Solution Approach 1:
The patent replaces the mechanical steel cable measurement system with an optical imaging system. Images are captured by a camera and processed to determine workpiece length, eliminating the need for physical cable connection and disconnection while maintaining measurement capability
Solution Approach 2:
The patent creates an optical copy (image) of the workpiece to perform measurements. By capturing images of the workpiece and analyzing them through image processing, the system obtains length measurements without physically contacting the workpiece, thus saving time and improving safety
2Productivity
If steel cables are permanently installed for measuring, then measurement is faster, but permanent installation is not possible in forging operations
Solution Approach 1:
The patent replaces the mechanical steel cable system with a non-contact optical system that can be permanently installed in the forging environment. The imaging system captures workpiece images through the die opening, enabling continuous measurement without interfering with the forging process
Solution Approach 2:
The patent transitions from one-dimensional linear measurement (steel cable) to two-dimensional image-based measurement. By capturing images from above through the die opening and processing them to extract length information, the system achieves measurement capability that adapts to the forging operation constraints
3Measurement precision
If visual or laser scanning methods are used to measure workpiece ends, then non-contact measurement is achieved, but the workpiece ends are hidden by the manipulator and die
Solution Approach 1:
The patent changes the measurement dimension by capturing images from above through the die opening rather than attempting to measure the hidden ends directly. The image processing system extracts length information from the visible portions of the workpiece in the images, overcoming the obscuration problem
Solution Approach 2:
The patent introduces an intermediary approach by using the die opening as a window to capture images of the workpiece. Instead of directly accessing the hidden ends, the system uses the available viewing angle through the die and processes the resulting images to determine workpiece length
4Measurement precision
If workpiece ends are measured directly, then length measurement is straightforward, but the ends change sideward positions and have deformed surfaces leading to measurement errors
Solution Approach 1:
The patent creates optical copies (images) of the workpiece at different positions and uses image processing to determine length. By analyzing multiple images and tracking features through processing, the system compensates for position changes and surface deformation, maintaining measurement precision
Solution Approach 2:
The patent performs continuous image capture and processing to track workpiece length throughout the forging operation. By continuously monitoring the workpiece in multiple images and processing them to extract length information, the system maintains accurate measurement despite position and surface changes
Data Source
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AI summary
The amount of elongation of a workpiece during forging can be determined by image processing to calculate the total amount of horizontal movement of marked patterns such as forging scale on the ends of the workpiece which move away from a forging bite during the forging blow. Images of marked patterns before and after a forging blow on both sides of the bite of a forging die are compared to determine the movement of the marked patterns and thus the movement of the ends of the workpiece. A method and system of determining the elongation and vertical displacement of a workpiece during forging is disclosed.