Non-Contact Inspection of Pillar Honeycomb Structures

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Solution Overview

Problem

Conventional inspection methods for pillar-shaped honeycomb structures with plugged portions often damage the projection medium, leading to increased inspection costs and reduced accuracy, as they require frequent replacement and are not suitable for structures with poor squareness.

Innovation Solution

An inspection method using a light diffusing film placed parallel to the second end face in a non-contact state, imaging a pattern of transmitted light with a camera to detect defective plugged portions without damaging the film, allowing for extended use and reduced replacement frequency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a projection medium is contacted with the second end face of the pillar-shaped honeycomb structure for inspection, then the plugged portions can be visualized as light spots for detection, but the projection medium may be damaged leading to impaired inspection accuracy and increased replacement costs

Engineering Contradiction:

Improveinspection accuracyVSAvoidprojection medium durability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

A light diffusing film is introduced as an intermediary between the light source and the pillar-shaped honeycomb structure. The film projects light spots corresponding to plugged portions without requiring direct contact with the structure's end face, thereby preventing damage while maintaining inspection accuracy through the film's diffusive light projection capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The conventional mechanical contact-based projection medium is replaced with a non-contact optical system using a light diffusing film. This substitution eliminates mechanical contact that causes damage, allowing the film to be used repeatedly without replacement while maintaining detection functionality through optical light diffusion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the projection medium is replaced frequently due to damage, then inspection accuracy is maintained, but inspection costs increase

Engineering Contradiction:

Improveinspection accuracyVSAvoidinspection cost efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The light diffusing film is designed as a durable, reusable component that does not require frequent replacement. By eliminating the damage issue through non-contact operation, the film becomes an economical long-term solution compared to conventional projection media that must be replaced frequently, thereby reducing inspection costs while maintaining accuracy

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Measurement precision

If conventional inspection methods are used, then plugged portions can be detected, but the methods are not suitable for structures with poor squareness and require frequent medium replacement

Engineering Contradiction:

Improvedetection accuracyVSAvoidsuitability for poor squareness structures

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The inspection method changes the operational parameters by using a non-contact light diffusing film instead of contact-based projection media. This parameter change enables the system to accommodate structures with poor squareness or irregular end faces, as the diffusing film can project light spots without requiring precise geometric alignment or contact with the structure surface

Inventive Principle:

Principle #35Parameter changes

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 method enables convenient and accurate inspection of pillar-shaped honeycomb structures without damaging the light diffusing film, reducing replacement costs and improving detection accuracy even for structures with poor squareness.

Implementation Method 1

imaging a pattern of transmitted light from the second end face according to arrangement of the plugged portions of the first cells and the second cells, with a camera via a light diffusing film placed parallel to the second end face

Methodology Applied

Scientific EffectLight diffusion: Scattering

Data Source

PatentUS11796441B2Inspection method and inspection system for pillar-shaped honeycomb structure

Publication Date: 2023.10.24 NGK INSULATORS LTD

AI summary

A method for inspecting a pillar-shaped honeycomb structure including the steps of: imaging a pattern of transmitted light from the second end face according to arrangement of the plugged portions of first cells and second cells, with a camera via a light diffusing film placed parallel to a second end face of the pillar-shaped honeycomb structure in a non-contact state with the second end face, which pattern is obtained by irradiating a first end face with light; and detecting a defective plugged portion(s) of the second cells based on an image of the pattern of transmitted light imaged with the camera.