Optical Inspection Head for Threaded Part Dimension Measurement
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Solution Overview
Problem
Current automatic inspection methods for geometric dimensions of parts are limited in accuracy and efficiency, as they often rely on traditional manual techniques and lack precise measurement capabilities, especially for complex shapes and threaded components.
Innovation Solution
The method involves directing an array of spaced planes of radiation at the part to create unobstructed planar portions, which are then measured to determine geometric dimensions, using a system with laser radiation and receiver modules to accurately capture and analyze the radiation patterns, allowing for precise measurement of geometric dimensions, including those of threaded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual gauging devices are used for measurement, then the system is simple to operate, but measurement precision and productivity are insufficient
Solution Approach 1:
The measurement system is segmented into multiple independent light line generators and light responsive sensors arranged around the part. Each sensor independently measures occlusion at different azimuthal locations, and the processor integrates these segmented measurements to achieve high precision geometric dimension measurement while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The patent replaces traditional mechanical gauging devices with an optical measurement system using light lines and photodetectors. This substitution eliminates mechanical contact, reducing wear and measurement errors while achieving non-contact high-precision measurement of geometric dimensions including threaded components
2Measurement precision
If automatic inspection methods with multiple light lines and sensors are implemented, then measurement precision improves, but device complexity increases
Solution Approach 1:
The inspection head apparatus is designed as a universal measurement system that can measure various geometric dimensions (diameter, circumference, thread parameters) of different parts using the same array of light lines and sensors. The processor automatically adapts the measurement configuration to the specific part geometry, achieving multi-functionality without proportionally increasing device complexity
Solution Approach 2:
Multiple light line generators and light responsive sensors are merged into a single integrated inspection head apparatus. The processor combines signals from multiple sensors simultaneously, merging the measurement functions into one coordinated system that achieves high precision through signal integration rather than through complex individual measurement mechanisms
3Productivity
If traditional inspection systems are used, then device complexity is low, but productivity and measurement efficiency are limited
Solution Approach 1:
The inspection system enables continuous measurement by rotating the part through the stationary array of light lines and sensors. Multiple geometric dimensions are measured continuously during the rotation process rather than requiring sequential manual measurements, significantly improving productivity and reducing measurement time while maintaining manageable device complexity
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 precise and efficient measurement of geometric dimensions, improving accuracy and efficiency in inspecting complex shapes and threaded components, reducing measurement errors and increasing productivity.
Implementation Method 1
Each of the unobstructed planar portions contains an amount of radiation which is representative of a respective geometric dimension of the part
Data Source
AI summary
A method and inspection head apparatus for optically measuring geometric dimensions of a part are provided. The method optically measures the geometric dimensions of a part having a part axis at an inspection station. The method includes directing an array of spaced planes of radiation at the part so that the part occludes each of the planes of radiation at spaced locations along the part axis to create a corresponding array of unobstructed planar portions of the planes of radiation. Each of the unobstructed planar portions contains an amount of radiation which is representative of a respective geometric dimension of the part. The method further includes measuring the amount of radiation present in each of the unobstructed planar portions.