Honeycomb Cell Defect Detection via Localized Light Intensity Thresholds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inspection methods for pillar-shaped honeycomb structures with plugged portions face challenges in accurately detecting defective cells due to differences in light intensity between cells adjacent to the outer peripheral side wall and those on the inner peripheral side, leading to decreased detection accuracy.
Innovation Solution
The method involves irradiating the end faces of the honeycomb structure with different wavelengths of light, capturing patterns of reflected and transmitted light, and using distinct criteria for cells adjacent to and not adjacent to the outer peripheral side wall to improve detection accuracy by measuring and comparing light intensities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the same inspection criteria are used for all cells, then the inspection process is simple, but the detection accuracy of defective cells is decreased due to light intensity differences between outer peripheral cells and inner cells
Solution Approach 1:
The patent applies different inspection criteria to different spatial locations of the honeycomb structure. Specifically, cells adjacent to the outer peripheral side wall use one set of light intensity thresholds, while cells not adjacent to the outer peripheral side wall use another set of thresholds. This local differentiation resolves the contradiction by adapting the inspection criteria to the local optical characteristics of each cell region, thereby improving detection accuracy without requiring overly complex global criteria.
2Measurement precision
If the intensity of transmitted light is adjusted to accurately identify positions of cells on the inner peripheral side, then the inspection accuracy of defective cells adjacent to the outer peripheral side wall is decreased
Solution Approach 1:
The patent implements location-dependent light intensity thresholds where cells adjacent to the outer peripheral side wall are evaluated against one set of thresholds, and cells not adjacent to the outer peripheral side wall are evaluated against another set. This allows accurate position identification for inner cells while maintaining reliable defect detection for outer cells, resolving the contradiction between position accuracy and overall inspection reliability.
3Object-affected harmful factors
If light is blocked from the outer peripheral side wall to suppress sneaking light, then the intensity of transmitted light from outer cells decreases, but detection accuracy is still compromised
Solution Approach 1:
The patent changes the parameter of light intensity thresholds based on cell location. By establishing different threshold values for cells adjacent to and not adjacent to the outer peripheral side wall, the system compensates for the reduced light intensity in outer cells caused by blocking measures, thereby maintaining measurement precision despite the harmful light sneaking being suppressed.
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
This approach enhances the detection accuracy of defective cells by distinguishing between cells based on their positions and light intensity patterns, allowing for precise identification of defective plugged portions.
Implementation Method 1
irradiating the first end face with light; capturing a pattern of transmitted light from the second end face
Implementation Method 2
capturing a pattern of reflected light from the second end face
Data Source
AI summary
A method for inspecting a pillar-shaped honeycomb structure includes steps of: capturing a pattern of reflected light from an end face with a camera and generating an image data of the pattern of the reflected light; distinguishing positional information of each of cells adjacent to an outer peripheral side wall and cells that are not adjacent to the outer peripheral side wall based on the image data of the pattern of the reflected light, and storing the distinguished positional information in a memory; capturing a pattern of transmitted light from the end face with the camera and generating an image data of the pattern of the transmitted light; measuring intensity of each transmitted light from the cells adjacent to the outer peripheral side wall to detect the cells having defective plugged portions that are adjacent to the outer peripheral side wall based on the generated image data of the pattern of the transmitted light and the positional information; and measuring intensity of each transmitted light from the cells that are not adjacent to the outer peripheral side wall to detect the cells having defective plugged portions that are not adjacent to the outer peripheral side wall based on the generated image data of the pattern of the transmitted light and the positional information.