Spiral Spring Shape Measurement Using Optical Imaging
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Solution Overview
Problem
Current quality inspection methods for spiral springs often fail to accurately determine if a spiral spring meets performance requirements, as deformation can lead to incorrect classification as a good product, even if the shape of specific parts meets design drawing criteria.
Innovation Solution
A shape measurement device and method that calculate the inter-coil space function, pitch function, and coil thickness function using photographic images or measurement data, enabling comprehensive inspection of spiral springs by assessing previously unchecked parameters such as space between coils, coil core distance, and coil thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional quality inspection methods are used to check only specific parts of the spiral spring, then the inspection process is simple and fast, but the measurement precision is insufficient and defective products may be misclassified as good products
Solution Approach 1:
The patent transitions from checking only specific discrete parts of the spiral spring to measuring the entire continuous shape profile of the spring. By capturing the complete shape data across all dimensions (inner diameter, outer diameter, free angle, coil geometry), the system achieves comprehensive quality assessment without requiring complex manual inspection procedures.
Solution Approach 2:
The patent uses photographic imaging to create a digital copy of the spiral spring's shape. This optical copy is then processed through image recognition algorithms to extract precise measurement data, replacing traditional physical measurement tools and enabling accurate, non-contact inspection of the entire spring geometry.
2Reliability
If comprehensive shape measurement is implemented to check all parameters, then the quality inspection accuracy improves, but the inspection time and processing complexity increase
Solution Approach 1:
The patent replaces traditional mechanical measurement tools and manual inspection processes with an optical imaging system and automated image recognition algorithm. This substitution enables simultaneous capture and analysis of all shape parameters (inner diameter, outer diameter, free angle, coil geometry) in a single operation, significantly reducing inspection time while improving reliability.
Solution Approach 2:
The imaging and processing system is designed to measure multiple parameters (inner diameter, outer diameter, free angle, coil shape) simultaneously using a single unified approach. This multi-functional capability allows comprehensive quality assessment without requiring separate inspection steps for each parameter, thereby maintaining fast processing speed.
Data Source
AI summary
Provided is a shape measurement device that measures a shape of a spiral spring formed in a spiral shape. The shape measurement device is provided with an input means and a function calculation means. The input means inputs a captured photographic image depicting the spiral spring or measurement data produced by measuring the shape of the spiral spring. The function calculation means uses the input photographic image or measurement data to calculate at least an inter-coil space function representing the space between neighboring coils of the spiral spring, a pitch function representing the distance between coil cores of neighboring coils of the spiral spring, or a coil thickness function representing the thickness of coils of the spiral spring.