Plant Alignment Using 3D Image Conversion
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Solution Overview
Problem
The existing methods for aligning large-sized apparatuses on construction sites are time-consuming and labor-intensive, especially when the positions of bolt holes do not match, leading to increased costs and extended schedules, and current alignment devices lack accuracy due to the absence of tolerance in design information.
Innovation Solution
An alignment method that involves converting two-dimensional image data of bolt holes into three-dimensional data, allowing for precise examination and modification of hole positions using jigs with marked targets, enabling accurate alignment and reducing the need for trial fitting at the construction site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If trial fitting is performed using actual apparatus at the factory, then alignment accuracy is improved, but time consumption and labor cost increase enormously
Solution Approach 1:
The patent uses a camera to capture images of the joining portions and creates image data that represents the actual apparatus. This digital copy is then used for alignment verification, replacing the need for physical trial fitting with actual apparatus while maintaining alignment accuracy.
Solution Approach 2:
The patent replaces the mechanical trial fitting process with an optical measurement system. A camera captures images of the joining portions, and image processing algorithms automatically verify alignment, substituting manual mechanical operations with automated optical-mechanical systems.
2Measurement precision
If trial fitting is performed on-site at the construction site, then alignment accuracy is improved, but device complexity and cost increase due to construction machinery and scaffolding
Solution Approach 1:
The patent performs alignment verification in advance at the factory before shipping the apparatus to the construction site. By conducting the alignment check preliminarily using image capture and processing, the need for complex construction machinery and scaffolding at the site is eliminated.
Solution Approach 2:
The patent uses digital image copies to represent the physical apparatus for alignment verification. This digital representation allows alignment checks to be performed remotely and preliminarily, avoiding the need to transport and assemble actual apparatus at the construction site for trial fitting.
3Productivity
If design information is used for alignment, then alignment speed is improved, but measurement precision deteriorates due to lack of tolerance information
Solution Approach 1:
The patent captures actual images of the joining portions and processes them to obtain precise position information. This real feedback from the actual apparatus state allows for accurate alignment verification that accounts for manufacturing tolerances, unlike theoretical design information alone.
Solution Approach 2:
The patent replaces reliance on theoretical design information with actual optical measurement of the apparatus. By using image processing to extract position data from captured images, the system achieves both speed (automated processing) and precision (actual measurement including tolerances).
Data Source
AI summary
The alignment method includes: an acquisition step of acquiring a first two-dimensional image data group on a acquired first target object, and acquiring a second two-dimensional image data group on a acquired second target object; a conversion step of converting the first two-dimensional image data group into first three-dimensional image data, and converting the second two-dimensional image data group into second three-dimensional image data; a designation step of designating the target serving as an origin in each of images based on the first three-dimensional image data and the second three-dimensional image data; a setting step of setting three-dimensional coordinates with respect to the origin in the first and second three-dimensional image data through use of information on the origin designated in the designation step; and a position examination step of examining positions of the corresponding targets in the first three-dimensional image data and the second three-dimensional image data.