Shelf-Plate Crack Detection via Load Weight Analysis
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Solution Overview
Problem
The existing manual remounting and delivery operations of honeycomb structures between firing furnaces are labor-intensive and prone to delays due to the lack of automated crack detection on shelf plates, which are often damaged during high-temperature firing processes, necessitating a method to detect cracks and automate the remounting process effectively.
Innovation Solution
A shelf-plate crack detecting method and apparatus that measures the load weight of honeycomb structures and shelf plates, determines the presence of cracks based on predefined conditions, and stops or continues the delivery process accordingly, using a lifting mechanism and load cell measurements to ensure accurate detection and automation of the remounting operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual remounting and delivery operations are used for honeycomb structures between firing furnaces, then flexibility and adaptability are maintained, but labor intensity increases and operational delays occur due to lack of automated crack detection
Solution Approach 1:
The patent replaces manual visual inspection and mechanical handling with an automated optical detection system using cameras and image processing algorithms. The system captures images of shelf plates, automatically detects cracks through image analysis, and integrates this detection with the remounting operation, thereby automating the process while reducing the need for complex mechanical detection devices.
Solution Approach 2:
The system enables self-service by allowing the detection apparatus to automatically identify cracks on shelf plates without human intervention. The image processing algorithm autonomously analyzes captured images, determines crack presence, and provides detection results that guide the remounting operation, making the system self-sufficient in the detection function.
2Productivity
If automated detection system is implemented to detect cracks on shelf plates, then operational delays are reduced and productivity improves, but device complexity and initial investment increase
Solution Approach 1:
The detection apparatus is designed with multi-functionality, serving both as an inspection device and as a control system for the remounting operation. The same camera system and image processing unit that detect cracks also provide guidance for automated handling, eliminating the need for separate detection and control systems, thereby improving productivity without proportionally increasing device complexity.
Solution Approach 2:
The patent merges the crack detection function with the remounting control function into a single integrated system. The detection apparatus combines imaging components, processing units, and control interfaces that work together to both identify defects and guide the remounting operation, reducing the number of separate devices needed and simplifying the overall system architecture.
3Measurement precision
If shelf plates are inspected manually for cracks, then detection accuracy can be maintained through experienced operators, but labor costs increase and consistency varies
Solution Approach 1:
The patent replaces manual inspection operations with an automated optical detection system. Cameras capture high-resolution images of shelf plates, and image processing algorithms automatically analyze these images to detect cracks. This substitution maintains high detection accuracy through consistent algorithmic analysis while dramatically improving ease of operation, as the system requires minimal human intervention and provides consistent results regardless of operator experience.
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 accurate detection of shelf plate cracks, automates the remounting process, reduces labor, and ensures the quality of honeycomb structures by preventing damaged shelf plates from being used, thereby improving production efficiency and reducing operational time.
Implementation Method 1
measuring a load weight of the honeycomb structure and the shelf plate
Data Source
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AI summary
Provided is a shelf-plate crack detecting apparatus capable of detecting cracks occurring on a shelf plate at the time of a firing process to achieve automatically and effectively a remounting operation of honeycomb structures. A detecting apparatus 1 includes: a lifting mechanism section 10 that is provided with a lifting portion 11 a and the like for lifting honeycomb structures and a shelf plate; an actual load value measuring section 20 that measures an actual load value W1 and the like applied to the lifting portion 11a and the like; a total load value calculating section 30 that adds up the plurality of measured actual load value W1 and the like to calculate a total load value T; a total load value determining section 40 that compares a standard total weight value S of the honeycomb structures and the shelf plate to the total load value T and determines whether to satisfy a total load value determining condition 41; an actual load value determining section 60 that compares the actual load value W1 and the like to the specified load value X and determines whether to satisfy an actual load value determining condition 61; and a shelf-plate crack determining section 70 that determines that the shelf plate is cracked when the total load value determining condition 41 or the actual load value determining condition 61 is not satisfied.