Contactless 3D Gear Inspection Using Paired Laser Modules
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Solution Overview
Problem
Current methods for dimensional inspection of mechanical components with toothing, such as gear systems, are inefficient due to manual or automated processes that are slow, lack precision, and require contact, which is not suitable for high-speed production in sectors like aeronautical and automotive, where complex shapes and defects are difficult to identify.
Innovation Solution
A contactless three-dimensional inspection device using pairs of laser measurement modules oriented to scan the teeth of mechanical components, allowing for rotational and translational motion to capture precise measurements of all dimensional characteristics, enabling fast and automatic inspection by building a virtual representation of the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or automated dimensional inspection machines are used, then inspection can be performed, but inspection speed is slow and cannot meet high production rates
Solution Approach 1:
The patent replaces mechanical contact-based inspection systems with a laser-based optical measurement system. The laser modules emit light beams that reflect off the component surface to capture dimensional data without physical contact, enabling high-speed scanning that meets production line requirements while eliminating the slow measurement speeds of traditional mechanical machines
Solution Approach 2:
The inspection system uses periodic rotational motion of the component combined with sequential laser scanning. The component rotates in controlled intervals while the laser modules systematically scan different angular positions, allowing complete surface inspection to be completed in seconds through repeated periodic measurement cycles rather than continuous slow scanning
2Measurement precision
If mechanical sensing machines are used, then dimensional characteristics can be measured, but the process is discontinuous and requires relatively lengthy inspection time
Solution Approach 1:
The laser measurement system operates continuously as the component rotates, with multiple laser modules scanning different angular positions simultaneously or in rapid succession. This continuous optical measurement process eliminates the stop-start nature of mechanical sensing machines, maintaining high measurement precision while dramatically reducing total inspection time to meet high productivity requirements
Solution Approach 2:
The inspection system divides the component surface into multiple angular zones and assigns different laser modules to scan specific segments. By segmenting the measurement task across multiple parallel scanning operations rather than sequential mechanical probing, the system achieves both complete dimensional coverage and high inspection throughput
3Adaptability or versatility
If separate machines are used for complex shapes, then all dimensional characteristics can be inspected, but the device complexity increases and inspection process becomes non-optimal
Solution Approach 1:
The inspection system uses a universal laser measurement platform that can inspect all dimensional characteristics of complex geared components through a single integrated setup. Multiple laser modules mounted on a common rotating structure provide omnidirectional scanning capability, eliminating the need for multiple specialized machines while maintaining full inspection coverage for complex geometries
Solution Approach 2:
The system adds the temporal dimension of rotation to the spatial scanning process. By measuring the component at multiple angular positions during rotation and synthesizing the data, the system achieves complete three-dimensional dimensional inspection of complex shapes using a single stationary laser module position, rather than requiring multiple machines from different directions
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 high-speed, precise, and reproducible inspection of mechanical components with toothing, determining measurement points across the entire surface in seconds, improving inspection speed and accuracy beyond existing solutions.
Implementation Method 1
at least one first pair of laser measurement modules
Implementation Method 2
laser measurement modules oriented towards a first face of a tooth and a second module oriented towards a second face of a tooth
Data Source
AI summary
A device is proposed for the contactless three-dimensional inspection of a circular, mechanical component (20) with toothing having a main axis of rotation, comprising:means for scanning the teeth, comprising at least one first pair of laser measurement modules (12A, 12B) and means for the rotational driving (11), about the main axis, of said component relative to the laser measurement modules;means for rebuilding a virtual three-dimensional representation of the component using data coming from said scanning means;means of dimensional inspection using the three-dimensional representation;each pair of modules comprising a first module oriented towards a first face of a tooth and a second module oriented towards a second face of a tooth;the modules being oriented relative to the component so that during a rotation of the component, the scanning means scan the first and second faces of each tooth throughout their thickness and depth.