3D Shaped Wire Measurement Using Multi-Angle Image Reconstruction
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Solution Overview
Problem
Existing measuring instruments are limited in their ability to accurately measure the shape and geometric parameters of shaped wire objects, particularly those with non-helical shapes, as they are specifically designed for helical springs and cannot accommodate objects of arbitrary shapes.
Innovation Solution
An instrument comprising a rotatable support, an image acquisition system with non-parallel optical axes, and a data processing unit that reconstructs a virtual sculpture of the object by subtracting volumes where the object is not present from an initial volume, allowing for the identification of wire centers and geometric measurements regardless of the object's shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measuring instruments are specifically designed for helical springs, then measurement precision for helical springs is improved, but adaptability to measure shaped wire objects of arbitrary shapes deteriorates
Solution Approach 1:
The measuring instrument is designed with a rotatable support and multiple image acquisition devices positioned at different angles, enabling it to capture images of shaped wire objects from multiple perspectives. The system can measure both helical springs and other arbitrary shaped wire objects by rotating the support and processing images through virtual sculpture reconstruction, thus achieving multi-functionality and adaptability while maintaining measurement precision.
Solution Approach 2:
The system transitions from two-dimensional image capture to three-dimensional virtual sculpture reconstruction by acquiring images from multiple angles and combining them. This dimensional transformation allows the instrument to accurately represent and measure complex three-dimensional shaped wire objects of arbitrary shapes, not limited to helical springs.
2Device complexity
If a single image acquisition device is used, then device complexity is reduced, but measurement precision for arbitrary shaped objects deteriorates
Solution Approach 1:
The system combines multiple image acquisition devices positioned at different angles (including perpendicular and inclined orientations) to capture comprehensive images of the shaped wire object. By merging the data from these multiple devices and processing them together through virtual sculpture reconstruction, the system achieves high measurement precision for arbitrary shapes while managing device complexity through integrated processing.
3Device complexity
If the support is fixed in position, then device complexity is reduced, but adaptability to measure objects of different orientations deteriorates
Solution Approach 1:
The support is designed to be rotatable rather than fixed, allowing it to dynamically adjust its orientation to position the shaped wire object at different angles relative to the image acquisition devices. This dynamic capability enables the measurement of objects with different orientations and shapes without requiring multiple fixed supports, thus improving adaptability while maintaining reasonable device complexity.
Data Source
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AI summary
It is disclosed an instrument and a method for measuring a wired shaped object, such as a spring for example. The spring is rotatably supported by a rotatable support of the instrument. An image acquisition system of the instrument comprises at least two image acquisition devices with optical axes not parallel to each other, each device acquiring a respective sequence of images of the spring at different rotation angles of the support. A data processing unit of the instrument reconstructs a virtual sculpture of the spring by eliminating, from an initial volume, the volume portions where the spring is not present, such portions being determined based on the sequences of acquired images. The data processing unit then identifies within the virtual sculpture a sequence of wire centers representing the path which the shaped wire follows to form the spring.