Spark Plug Insulator Bending Detection via Axial Sliding Pin
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Solution Overview
Problem
Conventional methods for inspecting spark plug insulators for bending suffer from low accuracy and efficiency, often leading to excessive detection of defects and decreased performance in ignition systems due to visual inspection methods.
Innovation Solution
A device and method utilizing an inspection pin and detecting means, such as an ink pad or optical sensor, to detect axial sliding movement of the spark plug insulator, allowing for precise identification of bending defects by preventing the pin from penetrating the through hole when bending exceeds a predetermined tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection method is used to detect bending of insulators, then inspection simplicity is maintained, but inspection accuracy deteriorates due to excessive detection of bending
Solution Approach 1:
The patent replaces the visual inspection method (manual/mechanical observation) with an automated optical detection system. The inspection device uses a camera to capture images of the insulator and through-hole, and automatically processes these images to detect bending, thereby eliminating the inaccuracy of human visual judgment while maintaining operational simplicity.
Solution Approach 2:
The patent introduces an intermediary detection mechanism (inspection pin or optical field) between the insulator and the detection system. The inspection pin physically interacts with the insulator to reveal bending through its position relative to the through-hole, while the camera acts as an intermediary to capture and analyze this information, providing objective and accurate measurement.
2Ease of operation
If visual inspection is performed by rotating insulators one by one, then inspection process is simple, but productivity decreases due to sequential inspection
Solution Approach 1:
The patent merges multiple inspection operations into a single integrated system. Instead of rotating and inspecting each insulator separately, the device combines image capture, processing, and bending detection into one automated operation that can handle multiple insulators simultaneously or in rapid succession, thereby maintaining simplicity while dramatically improving productivity.
Solution Approach 2:
The patent performs preliminary actions by pre-positioning the insulator in a fixed orientation and pre-configuring the detection system to automatically capture and analyze images without requiring manual rotation or sequential handling. This preliminary setup enables high-speed automated inspection while keeping the operational process simple.
3Measurement precision
If inspection pin is inserted into through hole to detect bending, then inspection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential detection function from a complex mechanical inspection system and isolates it into a simple yet effective inspection pin mechanism. By taking out only the critical element (the inspection pin that reveals bending through its position relative to the through-hole) and combining it with automated image capture, the system achieves high accuracy without excessive complexity.
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
Enhances inspection accuracy and efficiency, enabling the simultaneous inspection of multiple spark plug insulators and reducing the likelihood of false positives, thereby improving the overall performance and productivity in manufacturing.
Implementation Method 1
the detecting means is an ink pad that is impregnated with an ink, and the sliding movement of the spark plug insulator is detected by adhesion of the ink to a tip end of the spark plug insulator
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
A device for inspecting a spark plug insulator for bending, the spark plug insulator including a cylindrical body having a radially enlarged flange at an axially intermediate portion thereof, and a through hole formed in the body along an axial direction of the body. The inspection device includes an insulator supporting means for supporting the spark plug insulator so as to be slidable in an axial direction of the spark plug insulator, a linear inspection pin that is to be inserted into the through hole of the spark plug insulator supported by the insulator supporting means, and a detecting means for detecting a sliding movement of the spark plug insulator when the spark plug insulator is caused to slide in the axial direction thereof by the inspection pin by the inspection pin prevented from completely penetrating the through hole of the spark plug insulator owing to bending of the spark plug insulator which exceeds a predetermined tolerance.