Rotor Balance Inspection Using Image-Based Compensation Angles
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Solution Overview
Problem
Existing dynamic balance inspection methods for rotation devices like motors are inefficient due to the need for repeated manual compensation of unbalanced amounts, which can cause unstable wobbling and decreased output efficiency.
Innovation Solution
A dynamic balance inspection system and method that includes a first image-capturing unit, offset angle calculation unit, and compensation calculation unit to determine and compensate for unbalanced amounts in rotors using a dynamic balancer, with a positioning structure and counterweight portions, enabling precise angular and mass adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual compensation method is used for dynamic balance inspection, then the inspection process can be completed, but the efficiency of dynamic balance inspection cannot be increased due to repeated manual compensation
Solution Approach 1:
The patent replaces manual mechanical compensation operations with an automated image processing system. The image-capturing unit captures images of the rotor, and the processing unit automatically calculates unbalanced amounts and generates compensation instructions, eliminating the need for repeated manual compensation and significantly improving inspection efficiency
Solution Approach 2:
The system enables self-service dynamic balance inspection by automatically capturing images, calculating unbalanced amounts, and generating compensation instructions without requiring operator intervention for each compensation step. The system serves itself by processing its own measurement data to produce compensation results
2Measurement precision
If automated image capturing is used, then measurement precision is improved, but device complexity increases due to additional components
Solution Approach 1:
The patent introduces an image-capturing unit as an intermediary between the rotor and the measurement system. This intermediary captures visual information of the rotor's position and characteristics, converting physical rotor properties into image data that can be processed to determine unbalanced amounts with high precision
Solution Approach 2:
The system creates a visual copy (image) of the rotor and its positioning structure. By analyzing this optical copy rather than directly measuring physical dimensions, the system achieves precise measurement of rotor position and orientation while using relatively simple imaging equipment
Data Source
AI summary
A dynamic balance inspection system includes a first image-capturing unit, an offset angle calculation unit, a dynamic balance test processing unit and a compensation calculation unit. The first image-capturing unit is disposed on a first side of a rotor and is movable along an axis to capture a first image of a positioning structure and a second image of a plurality of first counterweight portions. The offset angle calculation unit obtains a first orientation corresponding to the positioning structure according to the first image, a second orientation corresponding to a first designated counterweight portion of the first counterweight portions according to the second image, and a first angular difference between the first and second orientations. The dynamic balance test processing unit receives a first compensation angle and a first compensation mass. The compensation calculation unit generates a first actual compensation position and a first actual compensation mass.