Vehicle Trim Breaking Line Inspection Using a Laser Sensor Matrix
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Solution Overview
Problem
Existing methods for producing predetermined breaking lines in vehicle interior trim parts require precise positioning and additional detection means to monitor residual wall thickness and inspect the contour and position of the breaking line, which can be cumbersome and less efficient.
Innovation Solution
A method using a sensor matrix to monitor residual wall thickness and inspect the contour and position of the breaking line by comparing individual measured values with stored reference values, allowing for interpolation to determine the actual position without additional detection means, and weighting individual sensor values for accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional detection means are used to monitor residual wall thickness and inspect the breaking line, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensor matrix serves multiple functions: it monitors residual wall thickness during laser processing, inspects the contour and position of the breaking line, and detects defects. This multi-functionality eliminates the need for separate detection devices, reducing device complexity while maintaining high measurement precision.
Solution Approach 2:
The sensor matrix utilizes the laser beam's own transmitted portion as the detection signal. The laser beam serves both as the processing tool and as the light source for detection, eliminating the need for separate detection light sources and reducing system complexity.
2Manufacturing precision
If precise positioning is required for breaking line production, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The sensor matrix provides real-time feedback on the actual position of the breaking line by detecting the transmitted laser beam. This feedback is compared with target position data, and deviations are used to adjust the laser beam positioning, enabling precise breaking line production with simplified operation through automated closed-loop control.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with an optical detection and control system. The sensor matrix detects position through light transmission, and the control system automatically adjusts positioning based on detected deviations, eliminating the need for complex mechanical positioning mechanisms.
3Device complexity
If a sensor matrix is used instead of additional detection means, then device complexity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The sensor matrix is divided into multiple individual sensors arranged in a matrix pattern. Each sensor independently detects the transmitted laser beam at its specific position, providing multiple measurement points simultaneously. This segmentation allows the system to achieve high measurement precision across the entire breaking line while using a single integrated sensor matrix device.
Solution Approach 2:
The patent transitions from one-dimensional linear sensors to a two-dimensional sensor matrix. This dimensional expansion allows simultaneous detection across the entire breaking line contour, providing comprehensive measurement data with a single device, thereby maintaining high measurement precision while reducing overall system complexity.
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 efficient monitoring of residual wall thickness and accurate determination of the breaking line's contour and position with reduced computational effort, identifying sensor defects and position deviations, and verifying part usability within specified tolerances.
Implementation Method 1
a laser beam scanning over the vehicle interior trim part along the predetermined breaking line ablates material
Implementation Method 2
a laser beam scanning over the vehicle interior trim part along the predetermined breaking line ablates material until a portion of the laser beam transmitted through the vehicle interior trim part is detected by individual sensors of the sensor matrix
Data Source
AI summary
A method for producing a predetermined breaking line in a vehicle interior trim part using a scanning laser beam and inspecting the predetermined breaking line. A transmitted part of the laser beam is detected by individual sensors of a sensor matrix at the individual holes of the predetermined breaking line and individual measurement signals are formed. At least some of these individual measurement signals are stored when a total reference signal is reached by a total measurement signal and compared with the individual reference values assigned to the processing locations. The contour and position of the predetermined breaking line produced can be evaluated from the comparison.