Probe Head Alignment for Curved Surface Coating Inspection
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Solution Overview
Problem
Existing methods for detecting defects and determining properties of coated components, especially on curved surfaces, require precise alignment of sensor systems, which is challenging for single production or small quantities and prone to errors without feedback, limiting their applicability to flat surfaces or requiring significant setup efforts.
Innovation Solution
A method involving projecting a pattern of known geometry onto the surface, capturing its image, and using mathematical relationships to determine and correct the probe head's orientation and distance relative to the surface, enabling automated or manual alignment for accurate defect and property detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If precise alignment of sensor system is required for defect detection, then measurement precision is improved, but device complexity and setup effort increase significantly
Solution Approach 1:
The patent applies feedback by projecting a reference pattern onto the surface, capturing its image, and using the captured pattern to determine the actual probe head position and orientation. This feedback loop automatically provides alignment information without requiring complex manual setup procedures, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The system performs self-alignment by using the projected pattern itself as the reference for determining probe head position. The pattern capture and evaluation automatically provide the alignment data needed, eliminating the need for external alignment tools or complex manual procedures, thus reducing device complexity while maintaining precision.
2Adaptability or versatility
If manual alignment of probe head is used for curved surfaces, then adaptability to different geometries is improved, but productivity and inspection efficiency decrease
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical system. The projection of the reference pattern and automated image capture and evaluation eliminate the need for manual probe head positioning, enabling the system to adapt to various curved surface geometries automatically while maintaining high inspection efficiency.
3Productivity
If automated positioning with robot is used, then productivity is improved, but device complexity and setup effort increase
Solution Approach 1:
The patent creates a universal alignment system that can work with different component geometries and probe head positions without requiring complex robot integration. The reference pattern method provides a geometry-independent approach to alignment that simplifies the overall system while maintaining automated inspection capabilities.
4Measurement precision
If precise alignment feedback is provided, then measurement precision is improved, but ease of operation decreases due to additional alignment steps
Solution Approach 1:
The system performs self-alignment automatically through the reference pattern method. The probe head position and orientation are determined autonomously by capturing and evaluating the projected pattern, eliminating the need for operator intervention in the alignment process. This maintains measurement precision while improving ease of operation.
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 and automated detection of defects and properties on curved surfaces by correcting the probe head's alignment, facilitating efficient inspection in single production or small quantities without the need for precise manual setup.
Implementation Method 1
at least one pattern of known geometry and dimensions is projected onto at least one surface area to be inspected and/or its surroundings using at least one projection light source. The image of the pattern on the respective surface is then captured by at least one optical detector unit
Data Source
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AI summary
In the method, using at least one testing head (5), using at least one projection light source (6), at least one pattern (1) with a known geometry and dimensioning is projected onto at least one surface (2.1) to be checked and/or the environment thereof. The image (3) of the pattern (2) on the respective surface is detected using at least one optical detector unit (4) and, on this basis, a comparison with the original geometry and dimensioning of the pattern (1) is carried out. In addition, using suitable mathematical relationships, the orientation (5a) of the testing head (5) is determined with the optical detector unit in at least one spatial angle and/or the distance (5b) of the testing head (5) from the surface (2.1) and/or the alignment of the measuring point of the testing head (5) and/or the thus-determined orientation (5a) and/or the distance (5b) of the testing head is corrected in relation to the respective surface or for the determining of errors and/or errors or properties on component surfaces or of component coatings are evaluated, are taken into account.