In-Line Porosity Measurement Using Basis Weight and Thickness

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Solution Overview

Problem

Existing methods for measuring porosity, such as those involving image analysis of cross-sections, require sampling and are not suitable for real-time in-line inspection, leading to potential delays in detecting defective products.

Innovation Solution

A method and device that measure the basis weight, thickness, and true density of inspection objects in real-time, allowing for non-contact porosity derivation while the objects are being conveyed, using techniques like X-ray fluorescence and spectroscopic interference laser displacement measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If cross-section image analysis is used to measure porosity, then measurement precision is improved, but productivity deteriorates due to sampling inspection and delayed feedback

Engineering Contradiction:

Improveporosity measurement precisionVSAvoidinspection speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical cross-section cutting and imaging system with a non-contact measurement system using light absorption principles. The measurement unit measures light absorption values of the inspection object in the manufactured state, eliminating the need for physical sectioning and enabling in-line real-time inspection while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a virtual model of the inspection object's internal structure by measuring light absorption values at multiple positions and deriving porosity distribution without physical destruction. This virtual copying approach allows repeated measurement of the same object in its original state, enabling real-time feedback while preserving the object.

Inventive Principle:

Principle #26Copying

2Device complexity

If sampling inspection is performed on production line, then device complexity is reduced, but reliability deteriorates due to inability to detect all defective products

Engineering Contradiction:

Improveinspection system complexityVSAvoiddefect detection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent implements continuous measurement of light absorption values across the entire inspection object as it passes through the measurement unit. By continuously deriving porosity values at multiple positions along the conveyance direction, the system achieves 100% inspection coverage rather than sampling, ensuring all defective products are detected while maintaining simple device architecture.

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If cross-section cutting is performed for porosity measurement, then measurement precision is improved, but loss of time increases due to sample preparation and delayed feedback

Engineering Contradiction:

Improveporosity measurement precisionVSAvoidtime for sample preparation and feedback

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary measurement of light absorption values while the inspection object is still in the manufacturing process, before any destructive testing is needed. By measuring in the manufactured state and deriving porosity distribution in advance, the system eliminates time-consuming post-production sample preparation and enables immediate quality feedback.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the time-consuming mechanical cutting and physical imaging process with instantaneous optical measurement. The light absorption measurement and porosity derivation occur in real-time during conveyance, reducing the measurement cycle from hours or days (for physical sectioning) to seconds, thereby eliminating loss of time while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 accurate, real-time porosity measurement of inspection objects during production, reducing the likelihood of defective products and improving feedback efficiency.

Implementation Method 1

using techniques like X-ray fluorescence

Methodology Applied

Scientific EffectX-ray fluorescence: Fluorescence

Implementation Method 2

spectroscopic interference laser displacement measurement

Methodology Applied

Scientific EffectSpectroscopic interference: Interference

Data Source

PatentUS11796442B2Porosity deriving method and porosity deriving device

Publication Date: 2023.10.24 HONDA MOTOR CO LTD

AI summary

Provided are a porosity deriving method and a porosity deriving device capable of deriving a porosity of an inspection object being conveyed. The porosity deriving method of deriving a porosity of the inspection object includes: a basis weight measuring step including measuring a basis weight of a specific part of the inspection object being conveyed; a thickness measuring step including measuring a thickness of the specific part of the inspection object being conveyed; and a porosity deriving step including deriving a porosity of the inspection object from the basis weight, the thickness, and a true density of the inspection object.