Gap Measurement Device for Overlapping Plates
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Solution Overview
Problem
Existing gap measurement methods, such as clearance gauges and prior art methods, face challenges in ensuring uniformity among workers and minimizing material damage when measuring gaps between overlapping plates, and are limited in measuring gaps with specific shapes like triangles formed by overlapping plates.
Innovation Solution
A gap measurement device and method utilizing a combination of sensors, including plate thickness, step, and displacement sensors, with an attitude determination unit and gonio stage, to accurately calculate and correct the gap measurement, reducing worker variability and material damage by measuring the gap between overlapping plates and applying pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a clearance gauge is used to measure gap dimensions, then the gap can be measured, but the measurement uniformity deteriorates due to worker-dependent insertion horizontality
Solution Approach 1:
The patent replaces the mechanical clearance gauge insertion method with an optical measurement system. A camera captures images of the gap from above, and image processing algorithms automatically calculate the gap width. This eliminates the need for workers to manually insert gauges horizontally, thereby improving measurement uniformity and reducing skill requirements.
Solution Approach 2:
The patent creates a digital copy (image) of the gap structure instead of physically interacting with it using a mechanical gauge. By capturing the gap's visual characteristics and processing the image data, the system obtains measurement information without physical contact, ensuring consistent results across different workers.
2Measurement precision
If a clearance gauge is inserted into the gap, then the gap dimension can be measured, but material damage occurs to the gap-forming material
Solution Approach 1:
The patent substitutes the mechanical insertion method with optical imaging. Instead of pushing a physical gauge into the gap (which damages the material), the system uses a camera to capture the gap from above and processes the image to determine dimensions. This completely eliminates mechanical contact and associated material damage.
Solution Approach 2:
The system creates a digital representation of the gap through imaging rather than physically inserting measurement tools. This copying approach allows measurement without physical intrusion, protecting the gap-forming material from damage while maintaining measurement accuracy.
3Adaptability or versatility
If traditional gap measurement methods are used, then gaps can be measured, but the device complexity increases when attempting to measure gaps in overlapping plate materials
Solution Approach 1:
The patent employs a universal imaging system that can measure various gap types, including those in overlapping plate materials. The same camera and image processing software used for simple gaps can handle complex overlapping structures, eliminating the need for specialized measurement devices for different material configurations.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with a unified optical imaging approach. Instead of requiring specialized gauges or tools for different gap configurations, a single imaging system captures all gap types, and software algorithms adapt to calculate dimensions for various structures including overlapping plates.
Data Source
AI summary
A gap measurement device for measuring a gap between an upper plate and a lower plate in a material formed of the upper plate and the lower plate that overlap with each other in the Z-axis direction, which is the thickness direction. The gap measurement device has an ultrasonic sensor that functions as a plate thickness measurement sensor for measuring a plate thickness that is the thickness of the upper plate, a laser sensor that functions as a step measurement sensor for measuring a step that is the distance between the upper surface of the upper plate and the upper surface of the lower plate, and a calculation unit for calculating the gap between the upper plate and lower plate by subtracting the plate thickness from the step.