Structured Light Sensor for Spray Foam Depth Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for measuring spray foam insulation depth and calculating material yield are subjective, inaccurate, and time-consuming, relying on mechanical tools and manual calculations, which do not allow for real-time adjustments during application, leading to potential material losses and suboptimal application parameters.
Innovation Solution
An electronic depth measurement system integrated into a sprayer's respirator mask or as an inspection tool, using a structured light sensor and software to provide a 3D map of the foam surface, calculating average and minimum depth, and material yield in real-time, enabling non-destructive, comprehensive measurements during and after application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical depth gage or colored pin method is used to measure spray foam depth, then measurement can be performed, but the measurement is subjective, inaccurate, and time-consuming
Solution Approach 1:
The patent replaces mechanical measurement tools (depth gages, colored pins) with an optical measurement system that uses a camera to capture images of the spray foam surface and automatically calculates depth based on image analysis, eliminating manual mechanical measurement processes
Solution Approach 2:
The system creates a digital copy (image) of the spray foam surface and processes this copy to determine depth measurements, allowing multiple measurements to be taken from the same visual record without physically touching or repeatedly measuring the foam
2Measurement precision
If mechanical depth gage is used to measure spray foam depth, then depth verification is possible, but the method leaves holes or punctures in the foam causing thermal weakness
Solution Approach 1:
The patent replaces mechanical penetration-based measurement (inserting depth gages into the foam) with non-contact optical measurement using a camera, thereby eliminating physical punctures that create thermal weaknesses
3Loss of information
If manual calculation method is used to determine material yield, then yield estimation is possible, but the process is tedious, inaccurate, and time-consuming
Solution Approach 1:
The patent replaces manual calculation processes with an automated computer-based system that uses image processing to calculate spray foam depth, area, and material yield instantaneously, eliminating tedious manual computations
Solution Approach 2:
The system performs self-measurement and self-calculation by automatically processing images to determine depth, area, and yield without requiring manual intervention for data collection or computation
4Manufacturing precision
If sprayer periodically stops to measure depth using mechanical method, then proper depth can be verified, but the application process is interrupted and efficiency is reduced
Solution Approach 1:
The patent enables continuous spray foam application by replacing intermittent mechanical measurement with continuous or near-continuous optical measurement that does not require stopping the spray process
Solution Approach 2:
The system maintains continuous spray foam application by using optical measurement methods that can be performed without interrupting the spraying process, keeping the useful action of foam application continuous
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
This system allows for accurate, instantaneous measurement of spray foam depth and yield, enabling real-time adjustments and improving application efficiency, reducing material losses and ensuring compliance with thermal and quality standards.
Implementation Method 1
using a structured light sensor and software to provide a 3D map of the foam surface
Implementation Method 2
The structured light sensor and software provide a three-dimensional map of the surface geometry
Data Source
AI summary
SPF (spray polyurethane foam) insulation applied in a commercial or residential building is an amazing but costly construction product. One reason is that application of SPF insulation requires large investment capital equipment and a specialized crew for each job. The work is further made difficult because determination of the performance and quality characteristics of the performed work is subjective and still dependent on only primitive tools for normal routine examination. We worked to solve this problem by designing, building, and testing a portable measurement and evaluation system capable of reading any, and all SPF substrates with reliable accuracy and repeatability. With this tool, the applicator or inspector can now efficiently and accurately determine the performance and quality characteristics of the spray foam job and make smart strategic decisions on-demand. Using our system, the average applicator can improve his productivity by 15% per job, can reduce his chemical consumption by 10% per job and the improve overall quality metric of the job. Using our system, the average inspector can reduce the inspection time by 80% per job and can increase the accuracy of his inspection by 20% per job.