Part Inspection Station Using Radiation Plane Array for Position Measurement
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Solution Overview
Problem
Current automatic inspection methods for parts lack precision in measuring geometric dimensions and positioning, often requiring manual adjustments and being prone to errors due to limitations in light beam alignment and radiation measurement techniques.
Innovation Solution
A method involving an array of planes of radiation that scan a part to create unobstructed planar portions, measuring the radiation present in these portions to obtain geometric measurements, and processing these signals to determine precise geometric dimensions, allowing for repositioning if measurements fall outside acceptable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional automatic inspection methods using light beams are used, then automation is achieved, but measurement precision deteriorates due to alignment limitations and errors
Solution Approach 1:
The patent replaces traditional mechanical alignment systems with an optical field-based measurement system. By using multiple planes of radiation and detecting their occlusion by the part, the system eliminates the need for precise mechanical alignment of light beams while maintaining automation. The measurement is based on optical field interactions rather than mechanical positioning, thereby improving measurement precision without sacrificing automation.
2Measurement precision
If multiple light beam generators and sensors are used, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple measurement functions into a unified optical field system. Instead of using separate light beam generators and sensors that require individual alignment, the invention combines multiple planes of radiation into a single integrated measurement approach. The system uses an array of planes of radiation that can be generated and detected as a cohesive unit, reducing device complexity while maintaining enhanced measurement capability through the multi-plane approach.
3Ease of operation
If manual adjustments are required for light beam alignment, then measurement flexibility is maintained, but productivity decreases and measurement errors increase
Solution Approach 1:
The patent implements a self-aligning measurement system where the optical field automatically adapts to the part being measured. The multiple planes of radiation are configured to inherently cover the measurement volume, and the system automatically detects occlusion patterns without requiring manual adjustment. This self-service capability eliminates time-consuming alignment procedures while maintaining measurement flexibility, thereby improving productivity and reducing measurement errors.
4Device complexity
If traditional gauging devices are used, then simplicity is maintained, but measurement precision and automation are limited
Solution Approach 1:
The patent transitions from traditional one-dimensional or two-dimensional gauging to a three-dimensional optical field measurement approach. By using multiple planes of radiation extending through the measurement volume, the system captures geometric information in three dimensions simultaneously. This dimensional expansion enables high measurement precision while maintaining relative simplicity through the unified optical field approach, overcoming the limitations of traditional gauging devices.
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 approach enables precise and accurate measurement of part dimensions, improving the reliability and efficiency of part inspection by ensuring geometric measurements align with predetermined acceptable values, reducing manual intervention and measurement errors.
Implementation Method 1
measuring the amount of radiation present in each of the unobstructed planar portions to obtain measurement signals
Data Source
AI summary
A method for precisely measuring position of a part to be inspected at a part inspection station is provided. The method includes positioning a part having a part axis relative to a measurement axis at the part inspection station and scanning the positioned part with an array of planes of radiation so that the part occludes each of the planes of radiation over a measurement interval of the part to create a corresponding array of unobstructed planar portions of the planes of radiation. Each of the unobstructed planar portions contains an amount of radiation which is representative of a respective geometric dimension of the part. The method also includes measuring the amount of radiation present in each of the unobstructed planar portions to obtain measurement signals and processing the measurement signals to obtain a geometric measurement between the axes at the measurement interval. The geometric measurement may be a distance between the axes or angle between the axes. If the geometric measurement is outside an acceptable range of geometric values, the method may further include repositioning the part until the geometric measurement between the axes at the measurement interval is within the acceptable range of geometric values.