Honeycomb Structure End Face Crack Detection via Dual-Angle Light
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Solution Overview
Problem
Conventional methods for inspecting the end face of honeycomb structures struggle to accurately distinguish between chipping and cracks, leading to inefficiencies in defect detection, as they often require time-consuming visual inspections and cannot reliably differentiate between these defects.
Innovation Solution
A method and device that utilize different light angles (40° or more and less than 40°) to acquire and compare image data, allowing for the detection of cracks by emphasizing distinct features of chipping and cracks through binarization and contraction processing, enabling precise identification of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection is used to distinguish chipping and cracks, then inspection accuracy may be maintained, but inspection time increases significantly
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses light reflection principles. The system irradiates the end face with light and detects reflected light patterns to automatically distinguish cracks from chipping, eliminating the time-consuming manual inspection process while maintaining or improving differentiation accuracy.
Solution Approach 2:
The patent changes the inspection parameters by using specific light irradiation angles and analyzing light reflection characteristics. By irradiating at angles of 45 degrees or more and detecting reflected light intensity, the system creates distinct detection patterns for cracks versus chipping, enabling rapid automated differentiation without manual intervention.
2Ease of operation
If conventional scanning methods are used to inspect the end face, then the inspection process is simplified, but the ability to distinguish between chipping and cracks is lost
Solution Approach 1:
The patent applies local quality by using different light irradiation angles for different detection purposes. Light is irradiated at angles of 45 degrees or more to specifically highlight crack features through reflection patterns, while the imaging system captures localized reflection characteristics that differentiate crack types from chipping, maintaining operational simplicity through automated angle control.
Solution Approach 2:
The patent introduces light reflection as an intermediary mechanism between the inspection system and the defects. By using light as a mediator that interacts differently with cracks versus chipping, the system automatically generates distinguishable detection signals, preserving process simplicity while enabling precise defect type differentiation through the light-mediated detection process.
3Measurement precision
If multiple inspection angles are used to improve defect detection accuracy, then measurement precision increases, but device complexity increases
Solution Approach 1:
The patent applies partial action by using a specific minimum light irradiation angle of 45 degrees or more, which is sufficient to create distinguishable reflection patterns for crack detection. This targeted angular threshold provides adequate detection precision without requiring complex multi-angle inspection systems, thereby controlling device complexity while maintaining high measurement precision.
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 high-accuracy and high-speed inspection of honeycomb structure end faces by distinguishing and detecting cracks, improving the sorting process for defective products.
Implementation Method 1
irradiating the first end face with light having an angle of 40° or more, the angle being an angle formed between the light and an axis being perpendicular to a placement face
Data Source
AI summary
A method for inspecting an end face, comprising: an arrangement step of arranging a honeycomb structure having a partition wall extending from a first end face to a second end face, at a predetermined position using the second end face as a placement face; a first image data for processing acquisition step of acquiring first image data for processing while irradiating the first end face with light having an angle of 40° or more, the angle being an angle formed between the light and an axis being perpendicular to the placement face of the honeycomb structure; a second image data for processing acquisition step of acquiring second image data for processing while irradiating the first end face with light having an angle of less than 40°; and a crack detection step of detecting a crack by comparing the first image data for processing with the second image data for processing.