Surface Finish Characterization Using Frequency Domain Size Data
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Solution Overview
Problem
In manufacturing, surface finish characterization of products like crankshafts is often incomplete due to intermittent sampling, leading to delayed detection of defects, which causes downtime and additional expenses, while in-line size measurements are typically discarded after ensuring diameter specifications, missing opportunities to indicate surface finish quality.
Innovation Solution
A method that transforms in-line size measurement data, such as diameter data, from the time-based domain to the frequency or wavelength domain using techniques like FFT, and compares the transformed data to predetermined limits to characterize the surface finish, allowing for real-time assessment of surface quality without increasing inspection time or adding hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface finish measurements are taken using statistical sampling, then measurement equipment can be simple and inexpensive, but defects may not be detected in time leading to downtime and additional expenses
Solution Approach 1:
The patent applies preliminary action by performing surface finish characterization using size measurement data that is collected in advance during normal manufacturing operations. The transformed size measurement data is analyzed to predict surface finish quality before actual surface measurements are taken, enabling early defect detection and preventing downstream assembly issues.
Solution Approach 2:
The patent implements beforehand cushioning by establishing predetermined acceptable ranges for transformed size measurement data that correspond to acceptable surface finish characteristics. These pre-established criteria act as a cushion or buffer that allows the system to detect and flag potential surface finish defects before they become critical failures requiring assembly disassembly.
2Loss of information
If in-line size measurements are taken on every product, then real-time monitoring is achieved, but the data is typically discarded after ensuring diameter specifications, missing opportunities to indicate surface finish quality
Solution Approach 1:
The patent applies parameter changes by transforming size measurement data from the time-based domain to the frequency domain or wavelength domain. This mathematical transformation (e.g., using Fast Fourier Transform) changes the representation of the data, revealing surface finish information that is not apparent in the original time-based measurements, thereby extracting additional value from existing data.
Solution Approach 2:
The patent implements universality by making the size measurement system perform multiple functions: it not only verifies diameter specifications but also characterizes surface finish quality. The same measurement device and data collection process serve dual purposes, eliminating the need for separate surface finish measurement equipment and reducing overall system complexity.
3Measurement precision
If surface finish gauges with small probe tip radius and high data density are used, then surface roughness measurement precision is improved, but inspection time increases and production efficiency decreases
Solution Approach 1:
The patent applies self-service by using the size measurement data that is already being collected during normal manufacturing operations to also provide surface finish characterization. The existing measurement system serves itself by extracting additional information (surface finish quality) from the size measurement data through mathematical transformation, eliminating the need for separate surface finish measurement operations.
Solution Approach 2:
The patent implements merging by combining surface finish characterization with size measurement operations. Instead of performing separate surface roughness measurements that would require specialized equipment and additional inspection time, the system merges both functions into a single measurement process, maintaining productivity while obtaining both size and surface finish information.
Data Source
AI summary
A system and method for characterizing surfaces includes using a measuring device to take size measurements of a manufactured product. The raw measurement data is transformed from a time-based domain to a frequency-based domain using a mathematical algorithm. The transformed size measurement data is then compared to predetermined limits within comparable frequency bands to characterize the surface of the manufactured product.