Cutting Tool Wear Surface Imaging for Accurate Wear Measurement
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Solution Overview
Problem
Existing methods for measuring the wear amount of a cutting tool's edge struggle to accurately detect the wear surface due to its darker appearance compared to the normal surface, making it difficult to automatically measure the wear amount effectively.
Innovation Solution
A wear amount measuring device and method that utilize a light emitting unit and imaging unit positioned to have a specular reflection relationship with a dummy object's wear surface, allowing for accurate specification of the wear surface based on brightness differences in the image, and optionally include a view angle adjustment unit to optimize the light's incidence angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional illumination methods (coaxial epi-illumination or small-sized ring light) are used, then the cutting edge can be imaged, but the wear surface cannot be selectively detected because it appears darker than the normal surface
Solution Approach 1:
The patent changes the illumination parameter from coaxial epi-illumination to oblique illumination at a specific angle (e.g., 45 degrees). This parameter change causes the wear surface to reflect light differently due to its altered surface geometry, making it appear brighter than the normal surface in the captured image, thereby enabling selective detection of the wear surface.
Solution Approach 2:
The patent effectively changes the brightness (optical property) of the wear surface in the image by using oblique illumination. The wear surface reflects more light toward the camera at the chosen illumination angle, causing it to appear brighter than the normal surface, which creates a visible contrast that facilitates automatic wear detection.
2Extent of automation
If the wear surface is detected based on brightness difference, then automatic measurement can be performed, but the boundary between wear surface and normal surface is not clear making accurate measurement difficult
Solution Approach 1:
By changing the illumination angle to oblique illumination, the patent enhances the brightness contrast at the boundary between the wear surface and normal surface. This creates a more distinct and clearer boundary in the captured image, enabling accurate automatic detection of the wear surface extent.
3Measurement precision
If the light emitting unit and imaging unit are positioned for specular reflection relationship with the wear surface, then the wear surface can be brightly imaged, but the device configuration becomes more complex
Solution Approach 1:
The patent sets the illumination angle to a specific value (e.g., 45 degrees) to achieve optimal specular reflection from the wear surface. This parameter optimization ensures that light reflected from the wear surface enters the camera effectively, making the wear surface appear bright and distinct in the captured image.
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
Enables accurate identification and measurement of the wear surface, allowing for precise calculation of the wear amount through image processing, even when the wear surface has varying angles, thereby improving the automation and accuracy of wear amount measurement.
Implementation Method 1
the light emitting unit and the imaging unit have a specular reflection relationship relative to the wear surface of the dummy object to be measured
Data Source
AI summary
A wear amount measuring device includes: a light emitting unit configured to emit light on an object to be measured having a wear surface; an imaging unit configured to obtain an image of the object; and a calculation unit configured to calculate a wear amount by specifying a wear surface of the object from the obtained image. A positional relationship between the light emitting unit, the imaging unit, and the object is set such that, when a dummy object to be measured having a wear surface is arranged in place of the object, the light emitting unit and the imaging unit have a specular reflection relationship relative to the wear surface of the dummy object. The calculation unit calculates the wear amount by specifying the wear surface based on a difference in brightness of the image.