Automated Honeycomb Outer Wall Inspection via Line Camera Imaging
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Solution Overview
Problem
Conventional visual inspection methods for detecting defects in the outer walls of honeycomb structure bodies are unreliable and inefficient, leading to inconsistent defect detection and increased inspection time, which hampers stable and productive industrial production.
Innovation Solution
A method utilizing a line camera to image the outer wall of a rotating honeycomb structure body, with image processing techniques such as binarization and noise removal to automatically detect defects, eliminating the need for human sensory inspection and ensuring consistent detection time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection by human operators is used to detect defects in the outer wall of honeycomb structure bodies, then the inspection can be performed with simple equipment, but the defect detection level fluctuates due to differences in visual power and fatigue degree, leading to unstable inspection results
Solution Approach 1:
The patent replaces the human visual inspection system with an automated image processing system comprising a camera, light source, and image processing unit. This substitution eliminates the variability inherent in human visual inspection (fatigue, visual power differences) while maintaining relatively simple equipment requirements. The camera captures images of the honeycomb structure outer wall, and the image processing unit automatically analyzes these images to detect defects, providing consistent and reliable detection results without the need for complex mechanical inspection devices.
2Reliability
If visual inspection is performed by increasing the number of inspecting persons to raise the defect detection level, then the defect detection capability is improved, but the inspection time per honeycomb structure body increases and productivity deteriorates
Solution Approach 1:
The automated image processing system enables continuous inspection of honeycomb structure bodies without interruption. The camera continuously captures images as the honeycomb structures pass through the inspection area, and the image processing unit continuously analyzes these images in real-time. This continuous automated inspection process maintains high defect detection levels without requiring multiple inspectors working in sequence, thereby reducing the inspection time per unit and improving overall productivity while ensuring consistent quality control.
3Device complexity
If visual inspection is performed without automation, then the equipment required is simple, but the inspection time per honeycomb structure body fluctuates due to fatigue degree and product dimension differences, making efficient industrial production difficult
Solution Approach 1:
The inspection system is designed to dynamically adapt to different product dimensions and inspection conditions. The image processing unit incorporates algorithms that can adjust to varying honeycomb structure sizes, patterns, and defect types. The system includes adjustable parameters for image capture (such as lighting conditions, camera positioning) and image analysis (such as threshold values, detection sensitivity) that can be optimized for different product specifications. This dynamic capability ensures consistent inspection performance across varying product dimensions without requiring manual reconfiguration, thereby reducing inspection time while maintaining simple equipment requirements.
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 enables stable and efficient defect detection without relying on human sensory functions, achieving consistent defect detection levels and significantly reducing inspection time, thereby improving productivity.
Implementation Method 1
imaging the outer wall of the honeycomb structure body by a line camera while rotating the honeycomb structure body; wherein the outer wall of the honeycomb structure body is imaged while irradiating the outer wall of the honeycomb structure body with light
Data Source
AI summary
There is disclosed a method of inspecting the outer wall of a honeycomb structure body which can be performed without relying on human sensory functions and in which a defect detection level and an inspection time per honeycomb structure body are constant, so that stable inspection can be performed. In a method of inspecting the outer wall of a honeycomb structure body 1 made of a ceramic material, while rotating the honeycomb structure body 1, the outer wall of the honeycomb structure body 1 is imaged by a line camera 2, and the thus obtained image is processed to judge whether or not a defect is present in the outer wall of the honeycomb structure body 1.