3D Optical Rope Measurement System
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Solution Overview
Problem
Existing measurement techniques for ropes and cables are prone to errors due to perspective issues, imperfect perpendicularity, and vibrations, often requiring operator presence in hazardous conditions and halting production or transport systems.
Innovation Solution
A calibrated optical system and method using multiple digital imaging devices capture and process digital images to reconstruct geometric parameters of ropes or cables in a three-dimensional space, overcoming perspective and vibration-related errors, enabling non-invasive, continuous measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-dimensional image processing techniques are used to measure rope geometric parameters, then the measurement process can be simplified, but measurement errors occur due to perspective location between the rope and camera
Solution Approach 1:
The patent transitions from two-dimensional image processing to three-dimensional measurement by using multiple cameras positioned at different locations. This dimensional change allows the system to capture the rope from multiple perspectives simultaneously, eliminating perspective errors and enabling accurate geometric parameter measurement without complex post-processing corrections.
2Device complexity
If cameras with linear sensors are used for measuring rope geometric parameters, then the measurement technique can be simplified, but errors occur due to imperfect perpendicularity between the sensor plane and rope axis, and due to vibrations during measurement
Solution Approach 1:
The patent employs multiple cameras positioned at different locations and orientations to capture the rope from multiple perspectives. This three-dimensional approach compensates for imperfect perpendicularity and vibration effects by providing redundant measurement data from different angles, allowing for more accurate geometric parameter extraction through spatial triangulation.
Solution Approach 2:
The system creates multiple virtual copies of the rope's geometric information by capturing it from different camera positions. These replicated measurements from multiple perspectives are then processed together to eliminate errors caused by single-view limitations, including perspective distortion and vibration-induced inaccuracies.
3Measurement precision
If contact measurement methods are used to measure moving ropes or cables, then measurement accuracy can be maintained, but the object cannot be measured continuously due to its movement
Solution Approach 1:
The patent replaces contact-based mechanical measurement systems with a non-contact optical measurement system using multiple cameras. This substitution allows the rope to be measured continuously as it moves through the measurement zone, eliminating the need to stop production or transport systems for inspection while maintaining measurement accuracy through photogrammetric reconstruction.
4Measurement precision
If operators perform measurements in hazardous environments, then direct observation and measurement can be achieved, but operator safety is compromised and production must be halted
Solution Approach 1:
The patent replaces manual contact measurement by operators with an automated optical measurement system consisting of multiple cameras and image processing units. This substitution eliminates the need for operators to enter hazardous environments directly, allowing continuous measurement of moving ropes or cables while improving operator safety and maintaining productivity.
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 accurate, continuous, and non-invasive three-dimensional measurement of geometric parameters of ropes or cables, allowing quality control without operator intervention and without halting production or transport systems, even in hazardous environments.
Implementation Method 1
a plurality of points of at least one region of the outer surface of the rope or cable are reconstructed photogrammetrically in a three-dimensional space from corresponding points on each digital image
Data Source
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AI summary
A three-dimensional measurement method of geometric parameters of a rope or cable (2) provides for obtaining a three-dimensional representation of at least a plurality of 3D contour points of the rope or cable and calculating the geometric parameters thereof, such as the diameter or the roundness or the axis. A calibrated three-dimensional optical measurement system (1) for measuring geometric parameters comprises a plurality of digital image acquisition devices (C0, C1, C2, C3) and a digital image processing device provided to perform the steps of the method.