Threaded Part Inspection Using Radial Laser Arrays
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Solution Overview
Problem
Current non-contact inspection systems are inadequate for accurately identifying defects in threaded workpieces, particularly in manufacturing settings where 100% inspection is required to ensure conformance to spatial form criteria, as they are limited in accuracy and capability.
Innovation Solution
A non-contact inspection system utilizing an array of lasers and photo-detection devices, such as CCD in line pixel arrays, mounted radially about a track, where parts move by gravity, allowing for improved measurement and detection of thread defects and geometric variations through the use of a novel method that aligns light sources and detectors perpendicular to the workpiece's longitudinal axis and parallel to the thread pitch, enhancing measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact probes are used to inspect threaded workpieces, then measurement capability is obtained, but wear occurs and positioning accuracy is required
Solution Approach 1:
The patent replaces mechanical contact probes with an optical measurement system using lasers and photo detectors. The system projects light sheets onto the workpiece and measures the reflected light to determine geometric parameters, eliminating mechanical contact and associated wear while maintaining measurement capability.
2Measurement precision
If contact probes are used for inspection, then dimensional evaluation is possible, but operation speed is slow
Solution Approach 1:
The optical measurement system captures geometric information through light reflection in a non-contact manner, enabling faster measurement cycles compared to mechanical probes that require physical contact and movement. The system can evaluate multiple parameters simultaneously through optical field analysis.
3Extent of automation
If conventional non-contact systems are used, then inspection capability is provided, but measurement accuracy for threaded parts is insufficient
Solution Approach 1:
The patent applies local quality by orienting the light sheets and photo detectors specifically parallel to the thread pitch direction. This targeted alignment ensures that the measurement system captures the critical thread geometry features with optimal resolution, improving accuracy for threaded parts specifically rather than using a generic non-contact approach.
Solution Approach 2:
The system uses multiple light sheets projected at different angles and positions around the workpiece, creating a three-dimensional measurement volume. The photo detectors capture reflected light from multiple perspectives, enabling accurate reconstruction of complex threaded geometries that conventional single-view non-contact systems cannot resolve.
4Reliability
If 100% inspection is implemented, then quality conformance is ensured, but inspection time increases
Solution Approach 1:
The optical measurement system enables rapid non-contact inspection of each workpiece as it passes through the measurement zone. Multiple geometric parameters are captured simultaneously through optical field analysis, allowing 100% inspection without the time penalty of mechanical measurement methods.
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 provides improved identification of conformance or non-conformance of threaded components, reducing the likelihood of defective parts in manufacturing and assembly applications by offering higher accuracy and capability in detecting flaws, thereby enhancing overall manufacturing quality.
Implementation Method 1
The array of lasers is mounted in radial fashion about a track in which the parts slide down. As a part slides down the track it will occlude the light generated from the array of lasers. The photo detection devices will measure the occluded light
Implementation Method 2
photo detection devices such as CCD in line pixel arrays or single channel photo detectors
Data Source
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AI summary
The present invention relates to an inspection device and particularly to a device using an array of light sources and photo-detection devices to evaluate threaded workpieces for conformance to spatial form criteria. The invention provides for improved identification of flaws in threaded components to identify the conformance of parts.