Optical Fastener Flushness Measurement System
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Solution Overview
Problem
Conventional systems for measuring the flushness of fasteners have low repeatability and require different gauges for various fastener sizes, making them inefficient for precise and accurate measurements.
Innovation Solution
A handheld system using a camera and multiple lights to illuminate the fastener and surface, capturing images to determine a normal map, depth map, and subsequently the flushness, with a computing system to process the data and provide precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual gauges are used to measure fastener flushness, then the measurement process is simple, but the measurement precision and repeatability are poor
Solution Approach 1:
The patent replaces manual mechanical gauges with an optical measurement system using cameras and controlled lighting. The system captures images of the fastener and surface, then uses image processing algorithms to automatically determine flushness, eliminating the need for physical contact and manual reading while achieving higher precision and repeatability
Solution Approach 2:
The system creates a digital copy (image) of the fastener and surface geometry rather than using physical contact gauges. By capturing optical information and processing it computationally, the system obtains measurement data without physically touching the fastener, thereby improving measurement consistency and eliminating operator-dependent variability
2Adaptability or versatility
If different gauges are used for fasteners of different sizes, then the measurement can be adapted to various fastener types, but the device complexity and time required increase
Solution Approach 1:
The patent employs a single universal optical measurement system that can measure all fastener sizes by capturing images and processing them computationally. The system uses adjustable lighting configurations and image processing algorithms that automatically adapt to different fastener dimensions, eliminating the need for multiple specialized gauges and reducing setup time
Solution Approach 2:
The system dynamically adjusts measurement parameters based on the captured images rather than requiring manual selection of fixed gauges. The image processing algorithms automatically adapt to the specific fastener size and geometry in the field of view, allowing the same hardware to accurately measure various fastener types without physical reconfiguration
3Reliability
If manual gauges are used for fastener measurement, then the equipment is simple, but the measurement repeatability is low due to pressure and direction sensitivity
Solution Approach 1:
The patent eliminates mechanical contact-based measurement by using optical imaging and computational analysis. The system captures images under controlled lighting and processes them to determine fastener flushness, removing the variability introduced by manual pressure application and contact pressure distribution that plagues traditional mechanical gauges
Solution Approach 2:
The system introduces light as an intermediary medium to transfer measurement information from the fastener to the camera sensor. By using controlled lighting patterns and image processing as intermediaries rather than direct mechanical contact, the system achieves consistent, repeatable measurements that are independent of operator pressure or contact conditions
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
The system allows for quick, accurate, and precise measurement of fastener flushness, with high repeatability and adaptability to different fastener sizes, improving measurement precision and reducing the need for multiple gauges.
Implementation Method 1
a camera to capture a plurality of images of the fastener and the surface while the lights sequentially illuminate the fastener and the surface
Implementation Method 2
a plurality of lights configured to illuminate the fastener and the surface
Data Source
AI summary
A system for measuring a flushness of a fastener in a surface includes a plurality of lights configured to illuminate the fastener and the surface. The system also includes a camera configured to capture a plurality of images of the fastener and the surface while the lights sequentially illuminate the fastener and the surface. The system also includes a computing system configured to determine a normal map of the fastener and the surface based at least partially upon the images, determine a depth map of the fastener and the surface based at least partially upon the normal map, and determine the flushness of the fastener with respect to the surface based at least partially upon the depth map.