Honeycomb Structure Inspection via Light Scattering and Gas Flow
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Solution Overview
Problem
Existing inspection methods for honeycomb structures, such as diesel particulate filters, face challenges in detecting small defects and those located near the outer periphery with reduced sensitivity, especially when defect sizes are comparable to or smaller than the average pore diameter.
Innovation Solution
An apparatus is developed that includes a fine grain introduction system, a light application system with high directivity, a current plate, and an air current formation system to inspect honeycomb structures. This apparatus uses a gas containing fine grains introduced into the honeycomb cells, with a controlled flow and light application to detect defects, and an air current formed along the outer periphery to enhance detection sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing inspection methods are used to detect defects in honeycomb structures, then the inspection process can be performed, but the sensitivity is reduced when detecting small defects or defects near the outer periphery
Solution Approach 1:
The patent introduces a light scattering intermediary mechanism to enhance defect detection. Light is introduced through the honeycomb structure and scattered by defects, making them visible to detectors. This intermediary light scattering process enables sensitive detection of small defects and peripheral defects that were previously undetectable with conventional methods.
Solution Approach 2:
The patent replaces conventional mechanical inspection methods with an optical inspection system. By using light introduction and scattering mechanisms, the system achieves non-contact, high-sensitivity detection of defects without the limitations of mechanical inspection methods, particularly for small and peripheral defects.
2Measurement precision
If a light source is introduced to visualize scattered light from defects, then defect detection is enabled, but air current diffusion and turbulence reduce detection accuracy
Solution Approach 1:
The patent employs pneumatic principles by introducing a gas flow system that creates controlled air currents. These air currents are used to transport particles through the honeycomb structure and control the flow patterns, reducing turbulence and improving the reliability of light scattering and defect detection.
Solution Approach 2:
The patent changes physical parameters of the inspection environment by controlling gas flow velocity, pressure, and composition. By optimizing these parameters, the system reduces air current diffusion and turbulence, thereby improving detection accuracy while maintaining the light scattering visualization capability.
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
The apparatus achieves high sensitivity in detecting small defects and those near the outer periphery of honeycomb structures by preventing air current diffusion and turbulence, allowing for precise identification of defects through scattered light visualization.
Implementation Method 1
a light application means of applying a light of high directivity so as to pass in parallel in the vicinity of the other face (fine grain discharge face) of the honeycomb structure
Implementation Method 2
an air current formation means causing a gas to flow along an outer periphery of the honeycomb structure in a direction from one face (fine grain introduction face) side toward the other face (fine grain discharge face) side of the honeycomb structure
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An apparatus for inspecting defects in a honeycomb structure, such as used in a diesel particulate filter, comprises a current plate (41) and means for introducing fine grains into cells (56) of the honeycomb structure defined by partition walls (58) at a fine grain introduction face (53), wherein fine grains penetrating the partition walls (58) are discharged from a fine grain discharge face (54). The discharged particles scatter light (51) emitted by a light source (30), said scattered light being detected by a CCD camera.