Honeycomb Structure Cell Deformation Inspection
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Solution Overview
Problem
Current methods for inspecting cell deformation defects in honeycomb structures are inefficient, often requiring long inspection times and risking damage to the partition wall during visual or pin gage inspections, and existing image processing methods are cumbersome due to the large number of cells that need to be evaluated.
Innovation Solution
A method that selectively measures the size of an inscribed circle for a subset of cells on the end face of the honeycomb structure, using imaging to determine cell deformation defects, where measurement cells and non-measurement cells are strategically chosen to reduce the number of measurements needed, thereby shortening inspection time and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by person is used to inspect cell deformation defect, then inspection can be performed, but inspection accuracy is low and inspection time is considerably long
Solution Approach 1:
The patent replaces manual visual inspection with an automated imaging system that captures images of the end face and uses image processing to measure cell dimensions. This substitution of mechanical/manual inspection with automated optical measurement significantly improves both inspection accuracy and reduces inspection time.
Solution Approach 2:
The patent creates an optical copy (image) of the honeycomb structure's end face and performs measurements on this copy rather than directly inspecting each cell physically. This allows rapid automated analysis of all cells without manual intervention, improving both accuracy and speed.
2Measurement precision
If pin gage inspection is used to inspect cell deformation defect, then cell size can be measured, but the pin gage contacts the partition wall causing damage
Solution Approach 1:
The patent replaces mechanical pin gage contact measurement with non-contact optical imaging and image processing. The imaging system captures the cell geometry and calculates dimensions from the image data, eliminating physical contact with the partition wall and preventing damage while maintaining measurement precision.
3Reliability
If image processing is used to inspect all cells for cell deformation defect, then comprehensive inspection is achieved, but inspection time is considerably long
Solution Approach 1:
The patent divides the end face into a grid pattern and systematically processes each cell or group of cells through image analysis. This segmentation allows automated high-speed processing of all cells while maintaining comprehensive coverage, achieving both complete inspection and reduced time through systematic automation.
Solution Approach 2:
The patent measures parameters for all cells (excessive action) to ensure complete inspection coverage, but uses efficient automated image processing to complete this comprehensive measurement quickly. The automated system can process all cells without the time penalty that would apply to manual inspection of the same comprehensive set.
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 allows for rapid and accurate inspection of cell deformation defects across all cells on the end face without damaging the honeycomb structure, significantly reducing the time required for inspection and maintaining high accuracy even with lower arithmetic processing capabilities.
Implementation Method 1
an imaging means for taking an image of the end face
Data Source
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AI summary
To provide a method for inspecting honeycomb structure that allows simply inspecting a deformation state of cells open to an end face of a honeycomb structure. The method for inspecting honeycomb structure sets a honeycomb structure as an inspection target. The method for inspecting honeycomb structure includes a process A. The process A measures a size of an inscribed circle 15 internally in contact with a partition wall 1. The partition wall 1 defines cells 2. The size of the inscribed circle 15 of at least the one cell 2 among these plurality of cells 2 open to a first end face of the honeycomb structure is measured. In the process A, when the cell 2 where the size of the inscribed circle 15 internally in contact with the partition wall 1 is to be measured is set as a measurement cell 2x and the cell 2 where the size of the inscribed circle 15 internally in contact with the partition wall 1 is not to be measured is set as the non-measurement cell 2y, at least the one cell 2 among the cells adjacent to the one measurement cell 2x is set as the non-measurement cell 2y and at least one cell among the cells 2 adjacent to the one non-measurement cell 2y is set as the measurement cell 2x.