Optical Pipe Thread Measurement with Axis-Aligned Sensing
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Solution Overview
Problem
Existing methods for optically measuring threads on metal pipes suffer from inaccuracies due to undefined pipe positions and variations in straightness, leading to reduced measurement accuracy and reproducibility, especially when pipes are not fully supported.
Innovation Solution
A method and device where the measuring head is freely positionable and includes optical measuring paths and position detectors, allowing precise alignment with the pipe's longitudinal axis, enabling accurate measurement by determining the pipe's spatial position and adjusting the measuring head accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pipe is not fully supported during measurement, then the measurement process is simpler and faster, but the pipe position becomes undefined and measurement accuracy decreases
Solution Approach 1:
The patent replaces mechanical support structures with an optical positioning system. Position detectors (optical sensors) detect the actual spatial position of the pipe's longitudinal axis, and this information is used to automatically adjust the measuring head's position. This substitution eliminates the need for complex mechanical support while maintaining measurement accuracy through software-based compensation.
Solution Approach 2:
The system dynamically changes the positioning parameters by detecting the pipe's actual position using optical sensors and adjusting the measuring head's coordinates accordingly. The control unit modifies the measurement parameters based on the detected spatial deviation, allowing accurate measurements without fixed mechanical support.
2Measurement precision
If the pipe is fully supported to ensure accurate positioning, then measurement accuracy improves, but the measurement process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces complex mechanical support structures with a lightweight optical detection system. Instead of using heavy support elements to fix the pipe position, the system uses position detectors to optically detect the pipe's longitudinal axis position and automatically compensates for deviations through coordinate transformation.
Solution Approach 2:
The patent introduces position detectors as an intermediary between the pipe and the measurement system. These optical sensors detect the pipe's actual position and transmit this information to the control unit, which then adjusts the measuring head's position. This intermediary enables indirect positioning without requiring direct mechanical support.
3Device complexity
If the measuring head is fixed in position, then the device structure is simpler, but it cannot accommodate various pipe diameters and thread types
Solution Approach 1:
The patent transforms the measuring head from a fixed position to a dynamically adjustable position. The measuring head is mounted on a manipulator that can move it in multiple degrees of freedom, allowing adaptation to different pipe diameters and thread types. The position is continuously adjusted based on real-time detection of the pipe's longitudinal axis position.
Solution Approach 2:
The patent creates a universal measurement system where the measuring head can measure different pipe diameters and thread types through automatic position adjustment. The system uses position detectors to identify the pipe characteristics and automatically configures the measuring head's position and orientation, making the device versatile without requiring multiple specialized fixtures.
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
Enhances measurement accuracy and reproducibility by ensuring the measuring head is aligned parallel to the pipe's axis, accommodating various pipe diameters and thread types, and includes features for collision detection and contamination management.
Implementation Method 1
at least one position detector to determine a spatial position of a longitudinal axis of the metal pipe
Implementation Method 2
an optical measuring path consisting of a light source and a camera arranged in the beam path of the light source for recording a shadow image of the external thread profile
Data Source
AI summary
A method and a device can be used for optically measuring a thread on an end of a metal pipe by at least one measuring head which is fastened to a manipulator. The measuring head is preferably freely positionable in relation to the metal pipe and has at least one optical measuring path for measuring the thread and at least one position detector. The method includes at least the following method steps: A) providing the metal pipe in a measurement position; B) determining the spatial position of a longitudinal axis of the metal pipe by means of the at least one position detector before and/or while the measuring head is positioned in a measurement position; C) aligning the measuring head parallel to the longitudinal axis of the metal pipe before and/or while the measuring head is positioned in the measurement position; and D) carrying out the optical thread measurement.