Non-contact Image Measurement for Shaft Workpieces
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Solution Overview
Problem
Conventional rear-projection image measurement methods require accurate axial alignment, which is difficult to achieve manually, leading to inefficiencies and inaccuracies when measuring shaft-shaped workpieces, especially those with non-circular cross-sections like triangular thread screws, due to reliance on contact measuring methods and operator skill.
Innovation Solution
An image-measuring apparatus and method that utilize a non-contact image measuring technique, allowing the workpiece to be arbitrarily placed on a rotating plate without axial alignment, using a lighting unit, image capturing unit, and central control unit to calculate the workpiece's axial position and contour size by analyzing shadow areas formed by the light beam, reducing the need for precise alignment and operator dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If accurate axial alignment is performed manually to measure shaft-shaped workpieces, then measurement accuracy is improved, but measurement time and operational complexity increase significantly
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated image processing system. The apparatus captures images of the workpiece, automatically identifies contour points, calculates the centroid position through coordinate computation, and determines axial alignment without requiring manual intervention. This substitution of mechanical alignment with automated optical and computational methods resolves the contradiction by achieving both high accuracy and efficiency
Solution Approach 2:
The measurement system performs self-alignment through automated image processing. The apparatus independently captures workpiece images, processes contour data, calculates centroid coordinates, and completes axial alignment without external manual operation. This self-service capability eliminates the time-consuming manual alignment process while maintaining measurement accuracy
2Measurement precision
If accurate axial alignment is performed manually to measure shaft-shaped workpieces, then measurement accuracy is improved, but ease of operation deteriorates
Solution Approach 1:
The patent replaces complex manual alignment operations with automated image processing and computational geometry. The system captures workpiece images, automatically extracts contour points, calculates centroid coordinates through mathematical computation, and achieves axial alignment without requiring skilled manual operation. This substitution dramatically improves ease of operation while maintaining measurement accuracy
Solution Approach 2:
The measurement system creates a digital copy of the workpiece through image capture and processing. Instead of requiring physical manual alignment, the system works with a digital representation (image data) of the workpiece, allowing automated contour analysis and centroid calculation. This copying approach simplifies operation by eliminating the need for skilled manual alignment techniques
3Adaptability or versatility
If contact measuring methods are used to measure non-circular cross-section workpieces, then measurement capability is improved, but measurement accuracy deteriorates due to operator dependency
Solution Approach 1:
The patent replaces contact-based mechanical measurement with non-contact optical imaging and automated image processing. The system captures images of the workpiece, automatically identifies contour points, and calculates dimensions through coordinate computation without human intervention. This eliminates operator dependency and its associated errors while maintaining the ability to measure various cross-section shapes
Solution Approach 2:
The measurement system creates a digital replica of the workpiece through image capture, allowing automated analysis of the contour geometry. This digital copying enables precise calculation of centroid positions and dimensional parameters without physical contact, eliminating the variability introduced by operator technique while preserving measurement capability for diverse cross-section shapes
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 quick and accurate estimation of axial position and contour size of workpieces, reducing manpower and costs while increasing measurement convenience and accuracy, as the apparatus can measure shaft-shaped workpieces without the need for precise axial alignment.
Implementation Method 1
The lighting unit is configured to generate a light beam traveling along an illumination path. The illumination path passes through the workpiece. The image capturing unit is disposed on the illumination path to receive the light beam. The workpiece blocks a part of the light beam so as to form a first workpiece blocking shadow area on the image capturing unit.
Data Source
AI summary
An image-measuring apparatus without axial alignment is configured to measure a workpiece. The image-measuring apparatus without axial alignment includes a rotating plate, a lighting unit, an image capturing unit, a central control unit and a rotary driving member. The workpiece is disposed on the rotating plate. The lighting unit is configured to generate a light beam to illuminate the workpiece to form a first workpiece blocking shadow area on the image capturing unit. The rotating plate and the workpiece are rotated through a rotational angle by the central control unit to form a second workpiece blocking shadow area on the image capturing unit. The central control unit calculates the first workpiece blocking shadow area and the second workpiece blocking shadow area to generate an axial position of the workpiece. There is a distance between an axial position of the rotating plate and the axial position of the workpiece.