3D Sheet Flatness Detection Using Structured-Light Data Fusion
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Solution Overview
Problem
Conventional methods for determining the flatness of steel plates during straightening are inefficient and subjective, relying on human judgment rather than objective measurement.
Innovation Solution
A device comprising a conveyor, gantry, industrial cameras, speed and vibration measurement units, and a multi-line laser, which calibrates and reconstructs the 3D flatness of the sheet material using structured-light measurement and data fusion to provide accurate and automated correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional straightening machines and flatting machines are used with naked eye judgment by operators, then the equipment is simple and easy to operate, but the flatness detection is inefficient and subjective
Solution Approach 1:
The patent replaces the mechanical/naked-eye inspection system with an optical measurement system consisting of lasers, cameras, and sensors. This substitution eliminates subjective human judgment and significantly improves detection efficiency while providing objective, quantifiable flatness measurements through coordinate system transformations and point cloud processing.
Solution Approach 2:
The patent introduces intermediate measurement devices (lasers, cameras, sensors) and a control system that acts as a mediator between the sheet material and the evaluation process. These intermediaries capture physical characteristics, convert them to digital data, and enable automated analysis, thereby improving efficiency without requiring direct human observation.
2Measurement precision
If multiple measurement devices (industrial cameras, speed measurement unit, vibration measurement unit, multi-line laser) are installed on the gantry, then measurement precision and automation are improved, but device complexity increases
Solution Approach 1:
The patent merges multiple measurement devices (industrial cameras, speed measurement unit, vibration measurement unit, multi-line laser) into an integrated measurement system mounted on a single gantry structure. This consolidation allows simultaneous multi-parameter measurement while sharing common support infrastructure, reducing overall system complexity compared to distributed separate systems.
Solution Approach 2:
The gantry structure serves multiple functions: it supports the measurement devices, provides a moving platform for scanning, and acts as a reference frame for coordinate transformations. This multi-functionality reduces the need for separate structures for each measurement component, thereby managing complexity while enhancing measurement precision.
3Measurement precision
If data fusion from multiple industrial cameras is performed to reconstruct complete 3D flatness, then measurement coverage and precision are improved, but processing complexity increases
Solution Approach 1:
The patent segments the measurement task across multiple industrial cameras, each capturing a portion of the sheet material. The control system then divides the data fusion process into manageable steps: individual camera calibration, point cloud generation per camera, and sequential data fusion. This segmentation makes the complex processing task tractable while achieving complete 3D reconstruction.
Solution Approach 2:
The patent transforms 2D images from multiple cameras into 3D point cloud data through coordinate system transformations and depth calculations. By adding the third dimension (depth/height), the system achieves complete 3D flatness reconstruction, enabling comprehensive flatness analysis that cannot be obtained from single-plane measurements.
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 solution enables an automated and intelligent system for detecting defects and improving the efficiency of steel plate straightening by reducing errors and enhancing the automation level of the production line.
Implementation Method 1
a multi-line laser, disposed between the at least two distance measurement devices
Implementation Method 2
The industrial camera unit is disposed on the first side of the beam and comprises at least two industrial cameras
Implementation Method 3
The vibration measurement unit is disposed on the second side of the beam and comprises at least two distance measurement devices
Data Source
AI summary
A device for detecting the flatness of a sheet material includes a conveyor, a gantry, a beam, an industrial camera unit, a speed measurement unit, a vibration measurement unit, a multi-line laser, a cable carrier, an industrial controller, and a control cabinet. The conveyor is disposed beneath the gantry and includes a plurality of pinch roll assemblies for feeding a sheet material. The beam is disposed on the gantry and includes a first side and a second side. The industrial camera unit is disposed on the first side of the beam and includes at least two industrial cameras. The speed measurement unit is disposed between the at least two industrial cameras. The vibration measurement unit is disposed on the second side of the beam and includes at least two distance measurement devices. The multi-line laser is disposed between the at least two distance measurement devices.