Seal Ring Inspection System Using Laser Scanners
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Solution Overview
Problem
Existing inspection systems for machine seals, such as CMM systems, are time-consuming and costly, especially when inspecting large seals with stringent tolerance specifications.
Innovation Solution
A seal ring inspection system that includes a chuck system for securing and rotating a seal ring, an inspection tool framework for supporting multiple inspection tools, and a control system for adjusting and operating the inspection tools, which capture image and spatial data of the seal ring during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a CMM system is used to measure seal geometry by probing discrete points, then measurement precision can be achieved, but inspection time increases to 10-60 minutes per seal
Solution Approach 1:
The patent replaces the mechanical CMM probing system with a non-contact optical measurement system using lasers and cameras. The laser projects patterns onto the seal surface while cameras capture the deformed light patterns, enabling precise 3D geometry measurement without physical contact. This substitution eliminates the time-consuming mechanical probing process while maintaining measurement precision through optical field interactions.
Solution Approach 2:
The patent implements periodic action by rotating the seal on a turntable while the laser and camera system remains stationary. This periodic rotation allows the stationary optical system to capture complete 360-degree geometry data of the seal over time, converting a potentially time-consuming multi-position measurement process into an efficient continuous scanning operation.
2Manufacturing precision
If detailed geometry inspection is performed on large seals with stringent tolerances, then manufacturing precision verification is improved, but inspection time and cost increase significantly
Solution Approach 1:
The patent creates a universal inspection system that can handle multiple seal types and sizes through programmable control. The system uses a database of seal specifications and automatically configures measurement parameters, laser patterns, and evaluation criteria based on the specific seal being inspected. This multi-functionality allows detailed precision inspection of various seal geometries without requiring separate dedicated equipment for each seal type, thereby maintaining high inspection throughput.
Solution Approach 2:
The patent creates a digital 3D copy of the seal geometry through laser scanning and camera capture. This digital model is then compared against the ideal seal design specifications in software, enabling detailed tolerance verification without physical contact. The copying approach allows rapid virtual measurement and analysis, significantly improving inspection speed while maintaining precise tolerance checking capabilities.
3Loss of information
If multiple inspection tools are used to capture comprehensive seal data, then measurement completeness is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple inspection functions into a single integrated station. The laser projector, multiple cameras (including overhead and side-view cameras), turntable, and control system are combined into one coordinated apparatus. This merging allows comprehensive 3D geometry capture from multiple angles simultaneously while using a unified control system to manage all components, reducing operational complexity compared to using separate inspection devices.
Solution Approach 2:
The patent introduces a computer control system and software as an intermediary that coordinates all inspection components. The control system manages the turntable rotation speed, triggers camera shutters at appropriate moments, processes laser pattern data, and compares measurements against specifications. This intermediary layer simplifies the operation of the complex multi-component system by providing centralized automated control and data integration.
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
The system enables rapid and efficient inspection of seal rings, reducing inspection time from minutes to seconds while ensuring compliance with stringent tolerance specifications, thus improving productivity and reducing costs.
Implementation Method 1
a plurality of laser scanners configured for capturing spatial data about the seal ring
Implementation Method 2
an imaging device arranged above the chuck system and directed downward to capture an image of a sealing surface
Data Source
AI summary
A seal ring inspection system may include a chuck system configured for securing a seal ring and an inspection tool framework arranged about the chuck system and configured to adjustably support a plurality of inspection tools relative to the seal ring. The system may also include a plurality of inspection tools adjustably arranged on the inspection tool framework including an imaging device and a plurality of laser scanners. The plurality of laser scanners may also include a surface laser scanner and a pair of diagonally directed profile laser scanners collectively configured for capturing a full profile of the seal ring.