Automated Setter Surface Inspection for Honeycomb Manufacturing
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Solution Overview
Problem
Conventional visual inspection of setter surfaces for honeycomb structures is inefficient and prone to human judgment variation, leading to increased defects and decreased yield in honeycomb structure production, particularly with thinner walls.
Innovation Solution
Implement a method using 3D scanners or cameras to image the setter's placement surface, analyzing pixel coordinate and height/luminance information to detect local abnormalities, and utilize an inspection device with image processing to objectively assess and remove defective setters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If visual inspection by humans is used to check the placement surface of the setter, then the inspection process is simple to implement, but the inspection efficiency is low and judgment variation occurs leading to decreased yield
Solution Approach 1:
The patent replaces the human visual inspection system with an automated imaging system using a camera or 3D scanner. The imaging device captures images of the placement surface, and an image processing unit automatically analyzes these images to detect local height abnormalities and dirt. This substitution eliminates human judgment variation and significantly improves inspection efficiency while maintaining simple implementation through automated processing algorithms.
2Measurement precision
If a height gauge is used to measure local unevenness on the placement surface, then measurement accuracy is improved, but the inspection time increases
Solution Approach 1:
The patent replaces the mechanical height gauge measurement system with an automated imaging and image processing system. The camera or 3D scanner captures the placement surface, and the image processing unit automatically calculates local height abnormalities by comparing pixel coordinates and height information. This automated process achieves high measurement precision equivalent to or better than manual height gauge measurement while dramatically reducing inspection time through parallel processing of multiple pixels simultaneously.
Solution Approach 2:
The patent analyzes the height information of all pixels in the placement surface image, which is more comprehensive than necessary for basic inspection. By processing excessive data (all pixel heights) through automated algorithms, the system achieves high measurement precision for local unevenness while the automation eliminates the time penalty that would result from manually analyzing each pixel, thus resolving the contradiction between precision and time.
3Manufacturing precision
If stricter quality control is implemented for the placement surface to accommodate thinner wall honeycomb structures, then the quality of honeycomb structures is improved, but the inspection complexity increases
Solution Approach 1:
The patent replaces complex manual inspection procedures with an automated imaging and image processing system. The system captures high-resolution images of the placement surface and uses algorithms to automatically detect local height abnormalities and dirt that could affect thin-walled honeycomb structures. This automation provides the strict quality control needed for thinner walls while keeping the inspection system itself relatively simple in terms of operation and maintenance.
Solution Approach 2:
The patent changes the inspection parameters by detecting local height abnormalities through pixel coordinate and height information analysis rather than relying on manual visual assessment. The image processing unit calculates height differences between pixels to identify abnormalities, providing quantitative measurement that enables stricter quality control for thin-walled structures. This parameter-based approach maintains manufacturing precision while avoiding complex inspection procedures.
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
Enhances inspection efficiency and accuracy, reducing judgment variation and improving the yield of high-quality honeycomb structures by identifying and removing defective setters.
Implementation Method 1
a step A1 of imaging the placement surface using a 3D scanner to obtain a first image of the placement surface, wherein each pixel constituting the first image has a coordinate information and a height information
Implementation Method 2
a step A2 of imaging the placement surface using a camera to obtain a second image of the placement surface, wherein each pixel constituting the second image has a coordinate information and a luminance information
Data Source
AI summary
A method for inspecting a setter, which is disposed between a shelf board and a honeycomb formed body when the honeycomb formed body is fired, the setter including a placement surface for placing the honeycomb formed body, the method includes: a step A1 of imaging the placement surface using a 3D scanner to obtain a first image of the placement surface, wherein each pixel constituting the first image has a coordinate information and a height information; and a step B1 of determining whether or not there is a local height abnormality on the placement surface based on the coordinate information and the height information of each pixel constituting the first image of the placement surface.