Tool Shape Measurement Device Using Optical Imaging
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Solution Overview
Problem
Existing tool shape measurement devices face challenges in accurately measuring tool dimensions due to complex tool shapes, requiring costly and space-intensive movement mechanisms for sensor or tool rotation, which increases costs and installation space requirements.
Innovation Solution
A tool shape measurement device with a contour detection unit, axis direction calculation unit, tool diameter measurement unit, and correction unit that calculates and corrects the apparent tool diameter using a calibrated positional and postural relationship between the imaging device and the rotating tool, eliminating the need for movement mechanisms by accounting for distortion in the tool contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a movement mechanism is used to rotate or translate the sensor or tool for measurement, then measurement accuracy is improved, but device complexity and installation space increase
Solution Approach 1:
The patent replaces the mechanical movement mechanism with an optical imaging system. Instead of physically moving the sensor or tool to capture contour data, the invention uses an imaging device to photograph the rotating tool from a fixed position. The contour information is extracted from the image data through image processing, eliminating the need for complex mechanical translation or rotation mechanisms while maintaining measurement accuracy.
Solution Approach 2:
The patent creates a visual copy of the tool contour through imaging. By photographing the rotating tool and extracting contour information from the image, the system obtains accurate dimensional data without physical contact or movement. The image serves as a replica that contains all necessary measurement information, replacing the need for physical measurement mechanisms.
2Measurement precision
If a movement mechanism is used to rotate or translate the sensor or tool for measurement, then measurement accuracy is improved, but installation space requirements increase
Solution Approach 1:
The patent replaces the mechanical movement mechanism with an optical imaging system. Instead of physically moving the sensor or tool to capture contour data, the invention uses an imaging device to photograph the rotating tool from a fixed position. The contour information is extracted from the image data through image processing, eliminating the need for complex mechanical translation or rotation mechanisms while maintaining measurement accuracy.
3Measurement precision
If correction tables are used for different contour shapes, then measurement accuracy is improved, but device complexity and data processing requirements increase
Solution Approach 1:
The patent changes the approach from discrete correction tables to continuous mathematical correction based on geometric parameters. Instead of selecting from pre-defined correction tables for specific contour shapes, the invention uses the extracted contour parameters (such as ellipse fitting results) to calculate correction amounts dynamically. This allows for accurate correction of any contour shape through mathematical relationships rather than lookup tables.
Data Source
AI summary
A tool shape measurement device includes: a contour detection unit that detects a tool contour from an image of a rotating tool that is taken; an axis direction calculation unit that calculates a tool axis direction that is an axis direction of the rotating tool on the basis of the tool contour; a tool diameter measurement unit that calculates an apparent tool diameter of the rotating tool on an imaging surface on the basis of a calibrated positional and postural relationship between an imaging device and the rotating tool, the tool axis direction, and the tool contour; and a tool diameter correction unit that calculates a distance between the imaging device and the rotating tool using the tool axis direction, and corrects the apparent tool diameter to an actual tool diameter by correcting distortion in the tool contour on the basis of the distance.