Hand-Held Edge Break Gage Using Structured Light
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Solution Overview
Problem
Existing methods for inspecting edge breaks in machined parts are time-consuming and inexact, and non-contact 3D surface profiling devices using structured light patterns are not user-friendly due to their size and portability issues, making it difficult to quickly and accurately inspect multiple parts in a manufacturing setting.
Innovation Solution
A hand-held edge break gage that projects a structured light pattern using a light source and optics system, combined with a digital camera for image capture and processing, allowing for fast and accurate 3D measurements of edge breaks, with optional robotic attachment for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical gage or optical comparator methods are used to inspect edge breaks, then measurement can be performed, but the process is time-consuming and inexact
Solution Approach 1:
The patent replaces traditional mechanical measurement systems (stylus gages, optical comparators) with a non-contact optical measurement system that uses structured light projection and digital imaging to capture and analyze edge break geometry, eliminating mechanical contact and significantly reducing measurement time while maintaining or improving accuracy
Solution Approach 2:
The patent transforms the measurement approach by changing from mechanical displacement measurement to optical parameter analysis, using digital image processing of structured light patterns to extract geometric parameters of edge breaks, enabling faster and more precise measurements
2Productivity
If non-contact 3D surface profiling devices using structured light patterns are used, then fast measurements can be obtained, but the devices are not user-friendly due to their size and portability issues
Solution Approach 1:
The patent divides the measurement system into separate functional components: a portable hand-held gage for field measurements and a separate image processing system for analysis, allowing the measurement device to be lightweight and portable while maintaining fast measurement capability
Solution Approach 2:
The patent introduces a portable hand-held gage as an intermediary device that captures structured light patterns in the field and transfers them for processing, enabling fast measurements to be performed portably without requiring the full processing system to be mobile
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 quick and precise 3D profiling of edge breaks, improving manufacturing efficiency by providing accurate data for quality control and wear determination without the need for cumbersome equipment, facilitating inspections across multiple locations.
Implementation Method 1
projects a structured light pattern using a light source and optics system
Implementation Method 2
combined with a digital camera for image capture and processing
Data Source
AI summary
A projector (20) projects a structured light pattern (46) along a first optical axis (44) onto a surface (80). A viewer (50) attached to the projector (20) receives a reflection of the structured light pattern (46) from the surface (80) along a second optical axis (54), and digitizes a two-dimensional snapshot. The optical axes (44, 54) are non-parallel, and they meet within a common field of view of the projector (20) and the viewer (50). A computer (61) interfaced to the viewer (50) receives the digitized snapshot, and analyzes it to mathematically model the surface for display and inspection. The projector and attached viewer are designed as a hand-held unit with a hand grip (66) and a trigger button (68) to trigger a snapshot. A guide tip (70) on the unit extends beside the two optical axes (44, 54) to the common field of view to position the hand-held unit.