Glass Plate Shape Prediction Using Universal Inspection Stand
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Solution Overview
Problem
Current shape inspection methods for glass plates, particularly for automotive windows, require simulation calculations for predicting shape data on actual inspection stands from universal inspection stands, which are time-consuming and resource-intensive, and often necessitate multiple inspection stands for different supporting points, leading to productivity and storage challenges.
Innovation Solution
A quality inspection method that calculates shape data using a computer program, allowing prediction of glass plate shapes on four-point supporting type actual measurement inspection stands from three-point supporting type universal inspection stands without simulation, employing weight patterns applied to all or specific supporting points, enabling efficient shape quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation calculation is performed to predict shape data on actual inspection stands from universal inspection stands, then measurement precision is improved, but inspection time increases and productivity decreases
Solution Approach 1:
The patent pre-calculates and stores the relationship between universal inspection stand measurements and actual inspection stand measurements in a conversion table before inspection. This preliminary action eliminates the need for time-consuming simulation calculations during actual inspection, thereby maintaining measurement precision while significantly improving productivity.
Solution Approach 2:
The patent creates a conversion table that copies the complex simulation calculation results into a simplified lookup format. Instead of performing full simulation calculations during inspection, the system copies pre-computed conversion relationships that can be quickly applied to predict shape data on actual inspection stands from universal inspection stand measurements.
2Measurement precision
If multiple inspection stands with different supporting points are prepared for different product models, then measurement precision for various glass shapes is improved, but device complexity and storage space requirements increase
Solution Approach 1:
The patent makes the universal inspection stand multi-functional by developing a conversion table that enables it to accurately inspect various glass plate shapes and models. Instead of requiring separate dedicated inspection stands for each product model, the universal stand with pre-stored conversion relationships can adapt to different inspection requirements, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent changes the operational parameters of the universal inspection stand by storing multiple conversion relationships corresponding to different glass plate shapes and supporting point configurations. This allows the same physical inspection stand to function as multiple different inspection stands by changing which conversion relationship is applied, thereby reducing the need for multiple physical devices.
3Manufacturing precision
If a gauge is used for shape inspection, then manufacturing precision is ensured, but the need for multiple gauges for different models increases storage space requirements
Solution Approach 1:
The patent creates a universal conversion table that can serve as a virtual gauge for multiple glass plate models and shapes. Instead of requiring physical storage of multiple large-scale gauges, the conversion table stored in computer memory provides the same manufacturing precision control function for all models, dramatically reducing storage space requirements while maintaining gauge functionality.
Data Source
Figure 1(a)~1(d)
Figure 2
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AI summary
The present invention provides a quality inspection method of a glass plate, which can predict the shape of the glass plate on a four-point supporting type actual measurement inspection stand from the shape of the glass plate on a three-point supporting type universal actual measurement inspection stand. In the present invention, based on three types of design shape data C1, C2 and C3 of a glass plate in a state that it is placed on a three-point supporting type actual measurement inspection stand and an actual measurement shape data Y1 of the glass plate in a state that it is placed on the actual measurement inspection stand, virtual errors ΔC2=C2-C1, ΔC3=C3-C1 and ΔY1=Y1-C1 at four supporting points of the glass plate are calculated; the degree of agreement of signs between the vector ΔY1 and ΔC2 or ΔC3 is evaluated to judge which of the pattern of C2 and the pattern of C3 is close to Y1; the degree of movement of weight distribution is obtained from the ratio between ΔY1 and ΔC2 or ΔC3 to obtain the average of the ratios at the virtual four supporting points; according to the degree of movement of weight distribution, a correction amount R=r(C3-C1) of a weight distribution close to the pattern of C3 or a correction amount R=r(C2-C1) of a weight pattern close to the pattern of C2, is obtained; the correction amount R=r(C3-C1) or the correction amount R=r(C2-C1) is subtracted from Y1-C1 to calculate a value corresponding to a difference Y2-A between a shape data Y2 of the glass on a desired actual measurement inspection stand and a design data A on the desired actual measurement inspection stand; and from the value corresponding to a difference Y2-A and a quality standard, the quality of the glass plate is judged.