3D Laser Measurement for Flooring Profile Quality Control
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Solution Overview
Problem
The existing methods for setting the profile of machined objects like laminate and hardwood flooring are time-consuming, requiring frequent quality checks and tooling adjustments, leading to inefficiencies and waste due to the need for stopping production lines and discarding products with incorrect profiles.
Innovation Solution
A real-time system using a three-dimensional laser measurement system to measure critical dimensions of flooring articles as they pass through a production line, comparing them to predefined reference dimensions and alerting operators of deviations, allowing for continuous production and potential on-the-fly adjustments to maintain tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical comparator inspection is used to set the profile, then measurement precision can be achieved, but productivity decreases due to production line stoppage
Solution Approach 1:
The patent replaces the mechanical/optical comparator inspection system with a laser-based measurement system that can operate while the production line is moving. The laser measures profile dimensions of flooring articles during conveyance, eliminating the need to stop production for quality checks while maintaining measurement capability.
Solution Approach 2:
The laser measurement system enables continuous quality control by measuring profile dimensions during production without interrupting the flow. The system continuously monitors articles as they pass through the production line, allowing real-time feedback while maintaining continuous production operation.
2Manufacturing precision
If frequent quality checks are performed during production runs, then manufacturing precision can be maintained, but loss of time increases due to repeated stoppages
Solution Approach 1:
The laser measurement system replaces repeated mechanical stoppage-and-inspect cycles with continuous non-contact measurement. The laser can measure multiple profile points sequentially as articles move through, providing frequent quality data without actual production stoppage.
Solution Approach 2:
The system performs measurement actions preliminarily during normal production flow rather than waiting for stoppage. By measuring profile dimensions as articles pass through the laser zone during conveyance, quality checks are integrated into the production process beforehand rather than requiring post-production inspection stops.
3Manufacturing precision
If tooling adjustments are made frequently to correct profile deviations, then manufacturing precision can be improved, but productivity decreases due to repeated adjustments
Solution Approach 1:
The laser measurement system provides real-time feedback on profile dimensions during production. By continuously measuring and comparing actual dimensions against target specifications, the system enables immediate detection of tooling drift or deviations, allowing for single corrective adjustments rather than repeated interventions.
Solution Approach 2:
The continuous measurement capability allows the production line to operate uninterrupted between adjustments. The laser system maintains continuous monitoring of profile quality, enabling the production process to run at full efficiency with minimal intervention, rather than requiring frequent stoppages for verification and adjustment.
4Measurement precision
If articles are inspected after production using optical comparators, then measurement precision is achieved, but loss of substance increases due to discarding defective products
Solution Approach 1:
The laser measurement system performs quality verification preliminarily during or immediately after the profiling operation, before articles proceed to cutting and finishing. By identifying profile deviations early in the process, the system prevents subsequent waste of materials that would be consumed in downstream operations on defective articles.
Solution Approach 2:
Real-time measurement feedback allows immediate identification and segregation of defective articles before they undergo further processing. The system provides continuous quality data that enables prompt corrective action, preventing the propagation of defects through subsequent manufacturing stages and reducing overall material waste.
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 continuous production with real-time quality control, reducing the time and waste associated with setting profiles and periodic quality checks, ensuring that products meet tolerance standards without halting production.
Implementation Method 1
At least a portion of a first face and a second face of the plurality of faces of the article can be irradiated with a laser of the laser measuring device to measure one or more profile dimensions
Data Source
AI summary
Methods and systems for use of a three dimensional measurement laser are disclosed. An example method can comprise receiving, at a laser measuring device, an article (e.g., a flooring article) having a plurality of faces, the article being conveyed in a direction. At least a portion of a first face and a second face of the plurality of faces of the article can be irradiated with a laser of the laser measuring device to measure one or more profile dimensions associated with the first and second faces of the article. The measured profile dimensions associated with the first face and the profile dimensions associated with the second face are compared to predefined reference dimensions. In response to a difference between measured profile dimensions associated with the first face and the second face and the predefined reference dimensions exceeding a threshold value, the article can be determined to be defective.