Shape Correction Device Using Point and Surface Sensors
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Solution Overview
Problem
Existing shape measurement devices take too long to measure the surface shape of molded products, making it difficult to measure warpage or bending in continuously manufactured products online and adjust manufacturing conditions accordingly.
Innovation Solution
A surface inspection device comprising a point measurement unit to measure predetermined points on the product's surface, a surface measurement unit to measure the shape of the surface including multiple points, and a computation unit to calculate the amount of deformation from a reference shape, allowing for high-accuracy evaluation in a shorter time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a stylus is brought into contact with the measurement surface for scanning, then measurement precision is improved, but measurement time increases
Solution Approach 1:
The patent combines multiple measurement functions into a single integrated system. The shape measurement device integrates the stylus contact measurement mechanism with a control unit that automatically performs parallel movement and orthogonal movement calculations, merging the measurement execution and data processing functions into one unified system that operates more efficiently
Solution Approach 2:
The patent implements dynamic adjustment of the stylus position through automated control. The control unit dynamically calculates the orthogonal movement based on real-time stylus position data and automatically adjusts the probe position, enabling adaptive measurement that responds to surface variations without manual intervention, thus improving both speed and accuracy
2Measurement precision
If contact scanning is performed to measure surface shape, then measurement precision is improved, but productivity is reduced
Solution Approach 1:
The patent implements a feedback control mechanism where the control unit receives real-time position data from the stylus, calculates the required orthogonal movement, and automatically adjusts the probe position. This closed-loop feedback system enables rapid iterative measurement and adjustment, significantly improving measurement speed while maintaining precision, thus enabling online measurement for continuous production monitoring
3Measurement precision
If repeated parallel movement and orthogonal movement are performed, then measurement precision is improved, but measurement time increases
Solution Approach 1:
The patent performs preliminary calculation of the orthogonal movement requirements based on initial stylus position data. The control unit pre-calculates the necessary probe adjustments before actual measurement scanning begins, allowing the stylus to follow an optimized path that minimizes repeated movements while ensuring measurement precision is maintained throughout the scanning process
Data Source
AI summary
Provided are a surface inspection device that evaluates a shape of a molded product with high accuracy in a shorter time than in the related art, a shape correction device, a surface inspection method, and a shape correction method. A point measurement sensor 201 that measures each of positions of predetermined points 102 set on a surface of an inspection target 101; a surface measurement sensor 202 that measures a shape of a predetermined surface 103 including the plurality of predetermined points 102 by simultaneously measuring positions of a plurality of points of the inspection target 101; and a deformation amount computation unit 3 that obtains an amount of deformation of the inspection target 101 from a reference shape based on the positions of the predetermined points 102 measured by the point measurement sensor 201 and a normal direction of the predetermined surface 103 measured by the surface measurement sensor 202 are included.