In-line Honeycomb Extrudate Inspection via Optical Feedback Control
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Solution Overview
Problem
The existing manufacturing processes for ceramic honeycomb bodies lack real-time inspection capabilities, leading to defects that are often discovered too late, resulting in increased labor, cost, and production inefficiencies, as well as potential scrapping of production runs.
Innovation Solution
An in situ inspection system that uses a line illuminator and detector to monitor the honeycomb extrudate for defects, generating a signal compared to a stored defect-free standard, allowing for real-time control of extrusion process parameters to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used after extrusion, then defects can be detected, but the inspection occurs too late to correct the extrusion process, resulting in increased labor, cost, and time
Solution Approach 1:
The inspection system is positioned to detect defects during the extrusion process itself, before the extrudate leaves the die. This preliminary detection allows the extrusion process to be corrected in real-time, preventing defective products from being produced rather than detecting and rejecting defects after production.
Solution Approach 2:
The system provides real-time feedback about defect conditions to the extrusion process control. By monitoring the extrudate surface characteristics during extrusion and comparing them to stored reference data, the system enables immediate process adjustment to correct defects as they occur.
2Productivity
If real-time inspection is implemented, then defects can be detected and corrected during extrusion, but additional equipment and system complexity are required
Solution Approach 1:
The patent replaces complex mechanical inspection systems with an optical inspection system using light sources and sensors. This substitution simplifies the overall system architecture while enabling real-time, non-contact inspection of the extrudate surface characteristics during the extrusion process.
3Reliability
If post-production inspection is conducted, then defects can be identified, but labor and manufacturing costs increase significantly
Solution Approach 1:
The system enables the extrusion process to self-monitor and self-correct by providing real-time feedback on product quality. The inspection system works autonomously during extrusion, automatically comparing current product characteristics to stored references and enabling process adjustment without requiring manual inspection or post-production sorting.
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 immediate detection and correction of skin and shape defects during the extrusion process, reducing waste and improving manufacturing efficiency by allowing for continuous, real-time feedback control of extrusion parameters.
Implementation Method 1
The detector is configured to detect the line illumination scattered from the outer peripheral surface of the extrudate
Data Source
AI summary
In-line inspection and control system to in-situ monitor an extrudate during extrusion. A light beam illuminates a line on the outside circumference of the extrudate skin recording the curvature. A master profile of the illuminated defect-free skin is recorded and compared to successive monitoring of the illuminated skin. Differences from the comparison indicate skin and/or shape defects. A real-time feedback to automatically adjust process control hardware reduces or eliminates the skin and shape defects based on the monitoring and comparison.