3D Socket Crimp Measurement for Hose Connector Fittings
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Solution Overview
Problem
Manual measurement of hose connector fittings using calipers results in wide variation and insufficient reproducibility, making it difficult to reliably and efficiently determine the acceptability of the crimping state.
Innovation Solution
A shape measuring device that detects distance data on the crimping state of a hose connector fitting using line sensors, generating three-dimensional shape data and calculating measurement data on the crimping state in a non-contact manner, reducing variation and improving reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement using a caliper is used to measure the outer diameter and crimping position, then the measurement process is simple and easy to operate, but the measurement data shows wide variation and insufficient reproducibility
Solution Approach 1:
The patent replaces the mechanical caliper measurement system with a non-contact optical measurement system using line sensors. The line sensors capture the three-dimensional shape of the socket's outer circumferential surface by detecting light reflection, eliminating the need for manual mechanical contact measurement. This substitution resolves the contradiction by providing highly reproducible measurement data through automated optical detection while maintaining operational simplicity through automatic data processing.
Solution Approach 2:
The patent creates a digital three-dimensional copy of the socket's outer circumferential surface using line sensor data. Instead of manually measuring physical dimensions, the system captures the complete surface geometry as digital shape data, from which outer diameter and crimping position are automatically extracted. This copying approach eliminates manual measurement variation and provides consistent, reproducible results across multiple measurements.
2Productivity
If manual measurement using a caliper is used, then the device complexity is low, but the measurement efficiency and reliability are insufficient
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated optical measurement system. Line sensors automatically capture the three-dimensional shape data of the socket, and a computer processing unit automatically calculates outer diameter and crimping position. This automation dramatically improves measurement efficiency and reliability while the increased device complexity is justified by the significant gains in productivity and measurement quality.
Solution Approach 2:
The measurement system performs self-service by automatically capturing shape data, calculating measurement parameters, and determining acceptability without manual intervention. The line sensors and computer processing unit work autonomously to complete the entire measurement process, eliminating the need for operators to manually measure and calculate, thereby significantly improving measurement efficiency.
3Reliability
If non-contact measurement using line sensors is used to detect three-dimensional shape, then the measurement data reproducibility is improved, but the device complexity increases
Solution Approach 1:
The patent replaces mechanical contact measurement with non-contact optical measurement using line sensors. The line sensors detect the three-dimensional shape of the socket's outer circumferential surface by measuring light reflection patterns, providing highly reproducible measurement data without the variability inherent in manual mechanical measurement. This non-contact approach enhances reliability while the added device complexity is offset by the elimination of manual operations.
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 non-contact measurement method significantly reduces data variation and improves reproducibility, enabling more accurate and efficient determination of the crimping state acceptability compared to manual caliper measurements.
Implementation Method 1
a distance data detecting unit configured to detect distance data on a distance to a surface of the socket
Data Source
AI summary
In a hose connector fitting, an outer circumferential surface of a socket is crimped toward a radially inner side thereof within a crimping range along an axis direction of the socket in the state where a hose is inserted into an annular space between an outer circumferential portion of a nipple and an inner circumferential portion of the socket. A shape measuring device includes: a sensor and a rotational moving unit that detect distance data from a reference position to the surface of the socket over a zone including at least the entire crimping range; a shape data generating unit that generates shape data representative the three-dimensional shape of the socket surface based on the detected distance data; and a measurement data calculating unit that calculates measurement data about the crimping state of the socket based on the shape data.