Optical Wear Depth Scanning for Remanufacturing Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for inspecting and remanufacturing machine components with worn surfaces are inefficient, as they lack precise measurement of wear, leading to iterative machining and material wastage, and increased machine downtime.
Innovation Solution
A system and method involving a scanning device that generates data points indicative of the depth of the worn surface relative to a reference plane, allowing for accurate determination of maximum depth and comparison to tolerance limits to guide remanufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods (visual inspection or known means) are used to inspect worn surfaces, then the inspection process is simple, but the measurement precision of wear extent is insufficient
Solution Approach 1:
The patent replaces conventional mechanical contact-based inspection methods with optical scanning technology. The scanning device uses optical fields to non-contactly measure the worn surface, generating precise depth profiles and wear extent data without physical contact, thereby achieving high measurement precision while avoiding the complexity of mechanical measurement systems
Solution Approach 2:
The patent introduces a scanning device as an intermediary between the worn surface and the inspection system. This intermediary captures optical information from the surface and converts it into precise digital measurements of wear extent, enabling accurate assessment without direct mechanical contact or complex measurement apparatus
2Reliability
If iterative machining and inspection process is followed to remove defects, then the surface defects can be removed, but material wastage increases and machine downtime increases
Solution Approach 1:
The patent performs preliminary action by using the scanning device to accurately identify the exact locations and extents of defects on the worn surface before machining begins. This preliminary detection allows for targeted removal of only the defective portions, preventing excessive material removal and reducing material wastage while ensuring surface quality
Solution Approach 2:
The patent implements feedback by using the scanning device to continuously monitor the worn surface during and after machining operations. The real-time or post-process scanning provides feedback on whether defects have been adequately removed, allowing for precise control of the machining process and preventing unnecessary additional machining that would waste material
3Reliability
If iterative machining and inspection process is followed to remove defects, then the surface defects can be removed, but machine downtime increases
Solution Approach 1:
The patent enables continuity of useful action by allowing the scanning device to operate during idle periods or in coordination with machining operations without requiring complete shutdowns. The non-contact nature of optical scanning permits inspection to occur with minimal interruption to the remanufacturing process, maintaining surface quality while reducing overall machine downtime
Solution Approach 2:
The patent performs preliminary inspection using the scanning device before machining begins and between machining passes. This preliminary and intermediate detection allows for optimized machining paths and reduced number of iterative cycles, thereby reducing the total time the machine must be down for remanufacturing while ensuring surface quality requirements are met
4Reliability
If machining operation is performed beyond print specifications to remove defects, then defects can be removed, but additional remanufacturing processes are required
Solution Approach 1:
The patent uses the scanning device to provide feedback on the exact extent of defects and the effectiveness of machining operations. This feedback enables precise control of machining depth and location, allowing defects to be removed while staying within print specifications when possible, thereby avoiding the need for additional complex remanufacturing processes such as material deposition
Data Source
AI summary
A method of determining wear of a worn surface of a machine component includes providing a scanning device at a distance from the worn surface. The method also includes moving at least one of the scanning device and the worn surface relative to the other and generating a set of data points via the scanning device. Each data point of the set of data points is indicative of a depth of a corresponding point on the worn surface relative to a reference plane. The method further includes determining a maximum depth of the worn surface based on the set of data points and comparing the maximum depth to a reference value to determine a next step in a remanufacturing process of the machine component.