Toroidal Radiation Screen for Moving Cable Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for measuring the external format and outline contour of elongated objects during manufacturing, such as cables, are inefficient due to limited accuracy and coverage, particularly in high-speed linear processes, resulting in helical measurements that are mostly statistical and not suitable for real-time quality control.
Innovation Solution
A toroidal structure with multiple radiation devices and recording devices operating at high frequencies to provide continuous, non-contact measurements of the complete surface of elongated objects, ensuring accurate diameter and contour assessments by generating a screen of radiation that envelops the object and analyzing imaging information as it moves through the measuring zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical devices perform rocking motion to-and-fro or rotation around the cable to measure circumference, then complete surface coverage is achieved, but measurement time increases and results become helical measurements of limited use
Solution Approach 1:
The measurement system is segmented into multiple stationary optical devices positioned at different angular positions around the cable. Each device captures a sector of the cable surface simultaneously, eliminating the need for time-consuming rotational or rocking motions while achieving complete surface coverage through spatial distribution of measurement points.
Solution Approach 2:
The invention transitions from temporal measurement (sequential scanning through rotation/rocking) to spatial measurement (simultaneous multi-point capture). By arranging multiple radiation and recording devices in a circular array around the cable, the system measures the entire circumference at one instant, converting a time-based problem into a space-based solution.
2Measurement precision
If optical systems measure cable diameter in one, two, three or four planes, then measurement capability is provided, but complete all-round surface measurement and real-time control are insufficient
Solution Approach 1:
The measuring apparatus is designed with universal functionality to perform multiple measurement tasks simultaneously: diameter measurement, outline contour analysis, and surface imperfection detection. The circular array of radiation and recording devices enables the system to capture complete all-round surface information in a single measurement cycle, making it adaptable to various cable types and measurement requirements without needing separate specialized devices.
3Productivity
If high-speed linear extrusion processes are used to manufacture cables, then productivity increases, but real-time quality control and continuous diameter monitoring become more difficult
Solution Approach 1:
The measurement system provides continuous monitoring of the cable as it passes through the extrusion process. Multiple stationary recording devices continuously capture cable dimensions and surface characteristics without interruption, enabling real-time quality control that keeps pace with high-speed linear extrusion processes. The system operates continuously alongside the manufacturing line, maintaining measurement accuracy despite high production speeds.
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 precise, real-time measurement of elongated objects with complete surface coverage, significantly improving measurement frequency and accuracy, allowing for continuous diameter control and imperfection detection, thereby enhancing quality assurance in manufacturing processes.
Implementation Method 1
a source of radiation within the toroidal structure configured by a multiplicity of radiation devices, disposed circumferentially around the toroidal structure within the measuring zone, to provide a screen of radiation to envelop the object as it moves therethrough
Implementation Method 2
a plurality of recording devices within the measuring zone, providing circumferential coverage overlap with the radiation devices and being adapted to analyze the imaging information of the emitted radiation from the object as it passes through the screen
Data Source
AI summary
An apparatus for non-contact monitoring of travelling objects being produced in an unguided linear process comprising: a toroidal structure with an open aperture defining a measuring zone, a source of radiation configured by a plurality of radiation devices circumferentially disposed within the measuring zone whereby the radiation source emits rays that generate a planar screen of radiation across the object circumferentially to envelop the object, a plurality of circumferentially disposed recording devices for receiving radiation from the radiation devices following interception of the rays by the objects, and analysis means for analyzing imaging information of the emitted radiation recorded by the recording devices thereby to provide a measure of the physical characteristics of the object.