Rectangular Wire Coating Thickness Inspection Using Laser Shape Measurement
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Solution Overview
Problem
Conventional methods for inspecting the thickness of a coating section on a rectangular wire are incomplete, as they only measure partial sections, leading to unreliable quality assurance due to positioning deviations and difficulty in controlling the thickness uniformly across the lengthwise and peripheral directions.
Innovation Solution
A method and device that include external shape measurement, position calculation, and determination steps to assess the thickness of the coating section across both the lengthwise and peripheral directions, using multiple laser irradiation points and precise positioning to ensure accurate measurement, even at swelling portions and inclined conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods (cutting end section or single-point measurement) are used, then the inspection process is simple, but the measurement coverage is incomplete and quality assurance is unreliable
Solution Approach 1:
The patent transitions from single-point measurement to two-dimensional external shape measurement across the entire rectangular wire. By measuring the external shape at multiple positions along the lengthwise direction and in the peripheral direction, the system achieves comprehensive coverage without requiring complex multi-point measurement devices, thus improving measurement accuracy while maintaining reasonable system complexity.
Solution Approach 2:
The inspection process is divided into distinct segments: external shape measurement, position calculation, and determination steps. The external shape measurement itself is segmented into measurements at multiple positions along the lengthwise direction and multiple points in the peripheral direction. This segmentation allows comprehensive inspection while keeping each measurement step relatively simple.
2Manufacturing precision
If the rectangular conductor is positioned without precise control, then the positioning process is simple, but the coating thickness becomes non-uniform due to positioning deviation
Solution Approach 1:
The patent replaces mechanical positioning control with a calculation-based approach. Instead of relying on precise mechanical positioning of the rectangular conductor, the system measures the external shape and calculates the actual position of the conductor. This substitution of mechanical control with measurement and calculation achieves high positioning precision without increasing operational complexity.
Solution Approach 2:
The system implements feedback by measuring the external shape and calculating the actual position of the rectangular conductor, then using this information to determine coating thickness. This feedback mechanism allows the system to compensate for positioning deviations automatically, achieving uniform coating thickness without requiring precise manual positioning.
3Reliability
If measurement is performed only at one point or end section, then the measurement process is quick, but the quality guarantee is insufficient
Solution Approach 1:
The patent performs external shape measurement at multiple positions along the lengthwise direction as a preliminary step before determining coating thickness. This preliminary measurement of the external shape provides comprehensive data that enables reliable quality assessment without requiring additional time-consuming measurement steps, as all necessary information is gathered in the initial measurement phase.
Solution Approach 2:
The external shape measurement serves multiple functions simultaneously: it provides data for determining the position of the rectangular conductor, enables coating thickness calculation at all positions, and ensures comprehensive quality coverage. This multi-functionality achieves reliable quality assurance without proportionally increasing inspection time, as one measurement process accomplishes multiple objectives.
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 allows for reliable inspection of the coating thickness, ensuring sufficient insulation properties and precise detection of thickness variations, thereby guaranteeing the quality of the rectangular wire.
Implementation Method 1
external shape measurement step, a position calculation step, and a determination step... an external shape of a rectangular wire across a lengthwise direction of the rectangular wire is measured
Implementation Method 2
external shape measurement step... using multiple laser irradiation points and precise positioning to ensure accurate measurement
Data Source
AI summary
A coating thickness inspection device (20) is provided with: a displacement gauge (25); a position calculation unit (28a); and a determination unit (28b). The displacement gauge (25) measures the external shape of a rectangular wire (30) across the lengthwise direction thereof (external shape measurement step). The position calculation unit (28a) determines the position of a rectangular conductor (31) within the rectangular wire (30) across the lengthwise direction of the rectangular wire (30) (position calculation step). The determination unit (28b) determines whether the thickness across the peripheral direction of a coating section (32) as calculated on the basis of the results obtained by the displacement gauge (25) and the position calculation unit (28a) satisfies a standard thickness across the lengthwise direction of the rectangular wire (30) (determination step).