Non-destructive Contour Measurement of Stacked Iron Cores
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Solution Overview
Problem
Existing inspection methods for stacked iron cores require destructive processes to ensure accurate contour measurement, leading to increased time and discarded stacks.
Innovation Solution
An inspection apparatus comprising a mounting base, a transmission plate, and an imaging apparatus with a moving mechanism to press the stack and align the optical axis perpendicular to the stack, allowing for non-destructive contour measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If one plate is peeled from the stack to form a single-layer plate for contour measurement, then the accuracy of contour measurement is improved, but the inspection time increases and the stack is destroyed
Solution Approach 1:
A transparent transmission plate is introduced as an intermediary between the imaging apparatus and the stack. This plate presses the stack from above to make the top plate surface perpendicular to the optical axis, enabling accurate contour measurement of the entire stack without peeling plates. The transmission plate mediates the interaction between the imaging system and the stack, allowing non-destructive inspection with high measurement precision.
2Measurement precision
If one plate is peeled from the stack for contour measurement, then the contour measurement accuracy is improved, but the stack is destroyed requiring discarding
Solution Approach 1:
The transparent transmission plate serves as a mediator that enables accurate contour measurement of the entire stack without destruction. By pressing the stack from above and making the top plate surface perpendicular to the optical axis, it allows the imaging apparatus to capture accurate contour information while preserving the stack's integrity, thus eliminating the need to discard the inspected stack.
Solution Approach 2:
The transmission plate enables the stack to be inspected in its original stacked state without requiring external preparation such as peeling plates. The stack itself serves as the measurement object without needing to be altered or dismantled, achieving self-service inspection that preserves the inspected item.
3Ease of manufacture
If the top plate is not perpendicular to the optical axis, then the imaging process is simpler, but the captured image is distorted and contour measurement is inaccurate
Solution Approach 1:
The transparent transmission plate acts as a mediator that corrects the orientation of the stack's top plate surface. By pressing down on the stack, it makes the top plate surface perpendicular to the optical axis of the imaging apparatus, thereby eliminating image distortion and enabling accurate contour measurement while maintaining the simplicity of the imaging process.
Solution Approach 2:
The transmission plate performs a preliminary action of pressing and orienting the stack's top plate surface perpendicular to the optical axis before the imaging process begins. This preliminary orientation adjustment ensures that the subsequent imaging captures accurate contour information without distortion, resolving the contradiction between simplicity and precision.
Data Source
AI summary
An inspection apparatus that accurately measures a contour of a stack without destroying the stack. An inspection apparatus according to an embodiment includes a mounting base on which a stack W is mounted, a transmission plate parallel to the mounting base configured to press the stack W from above, and an imaging apparatus positioned above the transmission plate, having an optical axis substantially perpendicular to the transmission plate configured to capture an image of the stack W from above. The stack W has a structure in which a plurality of thin plates are stacked on each other, and the thin plates adjacent to each other in a stacking direction are caulked together.