Portable Micrometer Shadow Profile Measurement
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Solution Overview
Problem
Existing portable micrometers for contactless measurement of elongated objects, especially in movement, face challenges such as requiring accurate alignment, physical contact, and high processing times, which limits their use in extrusion, drawing, and enameling processes, and increases production and management costs due to the need for multiple devices.
Innovation Solution
A portable micrometer with a light beam generator, light beam deflector elements, linear image sensors, and an electronic image processing component, allowing for contactless measurement by compensating for alignment variations and enabling manual use without physical contact, using two linear image sensors to detect light distribution and calculate object diameter independently of angle and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If portable micrometers are used manually for contactless measurement, then ease of operation is improved, but measurement precision deteriorates due to alignment variations
Solution Approach 1:
The system changes the measurement parameter from requiring precise angular alignment to measuring the shadow profile at any angle. By capturing the shadow cast by the object across the light beam and analyzing its dimensions, the system eliminates the need for precise orientation while maintaining measurement accuracy
Solution Approach 2:
The patent replaces mechanical alignment requirements with an optical measurement system that uses light beams and shadow detection. Instead of requiring mechanical precision in positioning and orientation, the system uses optical fields and image processing to achieve accurate measurements regardless of alignment
2Adaptability or versatility
If fixed micrometers are used at multiple points along the production line, then measurement coverage is improved, but device quantity and cost increase
Solution Approach 1:
The portable micrometer is designed as a universal device that can be positioned and operated at any location along the production line. Its portability and lack of fixed installation requirements allow a single device to perform measurements at multiple points, replacing the need for multiple fixed micrometers
Solution Approach 2:
The system transitions from static fixed installations to a dynamic portable device that can be moved and repositioned as needed. This dynamic capability allows one device to serve multiple measurement locations along the production line, reducing the total number of devices required
3Productivity
If linear sensors are used for rapid detection, then processing speed is improved, but measurement stability deteriorates due to vibration and movement
Solution Approach 1:
The system performs preliminary capture of the shadow profile before processing. By capturing the complete shadow image in a single rapid exposure and then processing it through analysis algorithms, the system achieves both speed and stability - the rapid capture freezes the movement, while subsequent processing provides stable measurement results
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 rapid, accurate, and independent measurement of elongated objects in movement, reducing measurement errors and processing times, and allowing for use at various points along production lines with a single device, thus lowering costs and improving operational efficiency.
Implementation Method 1
detect and measure the shadow of the product to be measured
Implementation Method 2
linear sensors (for example CCD - Charge-Coupled Device or CMOS - Complementary Metal-Oxide Semiconductor) to detect and measure the shadow
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
Portable device for contactless measurement of a size, such as the diameter, of small and medium sized objects, such as wires, bars or tubes, even in movement, which comprises a light beam generator (1), two light beam deflector elements (2, 4) located opposite each other, a measuring region (3), an enlarging lens (5), a light beam splitting device (6). The light beam is split into two parts to form two separate images of the object (14) to be measured, being perceived by two linear image sensors (7.1, 7.2) and processed by two electronic circuits (8.1 and 8.2) and by an electronic processing component (9).