Automated Optical Rope Testing for Defect Detection
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Solution Overview
Problem
Existing methods for testing ropes, particularly in applications like cableways, cranes, and elevators, are inefficient and unsafe, as they rely on human visual checks that can be affected by physical strain, poor lighting, and weather conditions, leading to potential errors and increased risk.
Innovation Solution
A computer-aided optical testing method that captures rope images, determines quality values based on target and actual longitudinal extensions, and discriminates defects using quality norms, allowing for automated, safe, and objective assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If human visual checks are used to test ropes, then the testing process can be performed with simple equipment, but the testing accuracy and reliability deteriorate due to human error, physical strain, and environmental factors
Solution Approach 1:
The patent replaces the human visual inspection system with an automated optical measurement system that captures images of the rope and uses image processing algorithms to objectively measure wire positions and detect defects, eliminating human error and physical strain while improving measurement precision
Solution Approach 2:
The patent creates a digital copy (image) of the rope's physical state and analyzes this copy through computational methods to determine wire positions and detect defects, allowing accurate measurement without direct human contact or exposure to hazardous conditions
2Device complexity
If human inspectors perform visual checks, then the testing method can be implemented with minimal technology, but the safety of the testing process deteriorates due to exposure to moving parts and hazardous environments
Solution Approach 1:
The patent substitutes human inspectors with an automated optical system that can safely observe and measure the rope from a distance, eliminating exposure to moving parts, high temperatures, and other hazardous conditions while maintaining testing capability
Solution Approach 2:
The patent introduces an optical intermediary system (cameras and image processing) that mediates between the hazardous rope environment and the safe analysis environment, allowing measurements to be taken without direct human contact with dangerous elements
3Device complexity
If manual visual inspection is used, then the testing process can be performed without automated systems, but the productivity and efficiency deteriorate due to time-consuming inspections and inability to perform tests during operation
Solution Approach 1:
The patent replaces slow manual visual inspection with automated optical capture and image processing that can rapidly analyze rope conditions, significantly increasing testing speed and enabling inspections to be performed during rope operation without stopping production
Solution Approach 2:
The patent enables continuous testing by capturing images during rope operation and processing them automatically, allowing the useful action of rope inspection to continue without interruption while maintaining high productivity through automated analysis
4Reliability
If image data is archived for permanent storage, then the ability to monitor rope condition over time improves, but the data storage requirements and processing complexity increase
Solution Approach 1:
The patent creates digital copies (images) of the rope's physical condition at different time points and stores these copies for comparison, enabling long-term monitoring of rope degradation and defect development without requiring physical preservation of the rope itself
Solution Approach 2:
The patent establishes a feedback system where archived images are compared with current images to detect changes in rope condition over time, providing continuous information about rope health and enabling predictive maintenance while managing data through systematic comparison protocols
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 method enables efficient, safe, and accurate rope testing by reducing human error, allowing for remote operation and permanent archiving of rope conditions, with the ability to monitor changes over time and detect defects quickly.
Implementation Method 1
optically capturing at least one portion of the rope, in particular, by means of an optical rope capturing device
Data Source
AI summary
A computer-aided method, system and computer program product are provided for optical testing of a rope. Such method includes: providing an image data set for at least one portion of the rope; providing target values of a pictorial longitudinal extension of the representation of wires relative to a pictorial longitudinal extension of the rope in the image data set; determining a pictorial longitudinal extension of the wires in the image data set, including adapting an estimated longitudinal extension to the image data set; determining at least one quality value using a quality norm as a function of the determined pictorial longitudinal extension of the wires and the target values of the pictorial longitudinal extension of the wires; discriminating pictorial positions within the image data set of the rope, where at least one quality value exceeds or falls below a predetermined, assigned quality threshold value; and providing the discriminated pictorial positions.