Hardness Tester Pattern Detection for Irregular Samples
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hardness testers face operability issues when measuring multiple samples with irregular orientations and intervals, leading to measurement errors and increased user intervention, as they require extensive recovery processes and may result in missed measurements.
Innovation Solution
A hardness testing system that includes a memory for storing measurement conditions defined with respect to a standard reference sample, a pattern searcher to detect identical samples, a pattern definer to establish a coordinate system and test position for each sample, and a measurer to execute automated hardness testing, allowing for efficient measurement of multiple samples with identical shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a parts manager is used to define test patterns for multiple samples, then measurement efficiency is improved for regularly arranged samples, but operability deteriorates when samples have irregular orientations and intervals
Solution Approach 1:
The system performs self-service by automatically detecting sample positions and orientations through image processing, and autonomously adjusting measurement parameters without requiring user intervention for recovery operations. The control unit automatically identifies sample arrangements and configures test patterns based on detected positions, eliminating the need for manual correction when samples are irregularly arranged.
2Reliability
If test patterns are defined for a fixed number of samples, then measurement consistency is improved, but measurement accuracy deteriorates when sample arrangements differ from expectations
Solution Approach 1:
The system dynamically adapts measurement parameters based on actual sample arrangements. The control unit modifies test patterns in real-time according to detected sample positions and orientations, allowing the measurement process to adjust to varying sample configurations while maintaining both consistency and accuracy.
Solution Approach 2:
The system incorporates feedback mechanisms where measurement results and sample detection data are used to automatically adjust subsequent measurement parameters. The control unit receives feedback from sample position detection and image processing, then modifies test patterns accordingly to ensure accurate measurements for each specific sample arrangement.
3Adaptability or versatility
If extensive recovery processes are required for irregular sample arrangements, then adaptability is improved, but time consumption increases
Solution Approach 1:
The system replaces manual mechanical adjustment and recovery operations with automated image processing and control algorithms. Optical detection and computer vision techniques substitute for physical sample repositioning and manual parameter adjustment, enabling rapid adaptation to irregular arrangements without time-consuming user intervention.
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
Improves operability by enabling automatic and accurate hardness testing of multiple samples with identical shapes, reducing the need for user intervention and minimizing measurement errors, even when samples are not regularly arranged.
Implementation Method 1
loading a predetermined test force on the sample with an indenter to form an indentation in a surface of the sample
Implementation Method 2
measures hardness of a sample based on dimensions of an indentation formed by pressing an indenter against the sample
Data Source
AI summary
A hardness tester includes a memory storing, as a parts program, definitions of measurement conditions including a coordinate system and test position defined with respect to an image of a standard reference sample; a pattern searcher performing a pattern searching process, with reference to a plurality of samples to be measured, using a pattern image based on the image of the standard reference sample, and detecting a number of samples having a shape identical to that of the standard reference sample, as well as a position and angle of the samples having the identical shape; a pattern definer defining a coordinate system and test position for each of the samples having the identical shape based on the position and angle of each of the samples having the identical shape; and a measurer measuring the hardness of the samples for which the coordinate system and test position have been defined.