Spark Plug Inspection Using Regression Correction
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Solution Overview
Problem
Existing methods for manufacturing spark plugs lack sufficient accuracy in inspecting dimensions critical for ignition performance, particularly the spark gap, due to limitations in correction techniques used.
Innovation Solution
A method involving imaging and measuring target parts and reference standards with different known dimensions, using regression analysis to derive correction values for improving measurement accuracy, and displaying these values for operator confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a correction equation derived from one reference standard is used, then the manufacturing process is simple, but the inspection accuracy is insufficient
Solution Approach 1:
The correction process is segmented into multiple independent reference standards with different known dimensions, allowing the system to handle complex correction requirements through multiple simple, manageable reference points rather than one complex correction equation
Solution Approach 2:
The patent changes the parameter of reference standards from a single standard to multiple standards with different known dimensions, enabling more accurate correction by capturing variations in measurement conditions across different dimensional parameters
2Measurement precision
If multiple reference standards with different known dimensions are used, then the inspection accuracy is improved, but the measurement process becomes more complex
Solution Approach 1:
The regression line is derived in advance from multiple reference standards with different known dimensions, so that when actual inspection is performed, the correction can be quickly applied using the pre-established regression equation, improving measurement efficiency
Solution Approach 2:
The patent creates a mathematical model (regression line) that copies the relationship between known dimensions and measured dimensions from reference standards, allowing this relationship to be reused for correcting measurements of actual spark plug components without repeatedly performing complex measurements
3Measurement precision
If image processing is used for dimension inspection, then the manufacturing process is automated, but the measurement accuracy is insufficient due to pixel dimension errors
Solution Approach 1:
The patent implements feedback by using the regression line derived from reference standards to correct the measured dimensions obtained through automated image processing, continuously improving measurement accuracy by comparing measured values against known reference values and applying corrective calculations
Solution Approach 2:
The patent changes the parameter of pixel dimension from a fixed value to a corrected value derived from regression analysis, allowing the automated image processing system to compensate for pixel dimension errors and achieve higher measurement accuracy while maintaining automation
Data Source
AI summary
A method for manufacturing a spark plug including a reference standard imaging step of imaging a plurality of reference standards to obtain a plurality of reference images, each reference standard having a reference part with a predetermined known dimension; a reference standard measuring step of measuring a measured dimension or a measured number of pixels of the reference part in the plurality of reference images; a regression line deriving step of obtaining a regression line by the least squares method from: the measured dimension or the measured number of pixels of the plurality of reference standards; and the known dimensions; and a determining step of determining whether a target part in a target image is within a predetermined range based on a correction value obtained by correcting a measured dimension of a target part by using a relational expression describing the regression line.