Vibrating Blade Wear Measurement Using Non-Contact Image Detection
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Solution Overview
Problem
Existing methods for determining the dimension between the back and the cutting edge of a vibrating blade in flexible material cutting are inaccurate and require mechanical contact, leading to potential blade deterioration and frequent manual adjustments.
Innovation Solution
A method involving digital image acquisition and processing to calculate a filtered dimension between the blade's cutting edge and back, using a camera to capture images of the blade in various vibration states, allowing for accurate wear measurement without mechanical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical contact measurement methods are used to measure blade wear, then measurement can be performed, but the cutting edge of the blade may be deteriorated
Solution Approach 1:
The patent replaces mechanical contact measurement methods with optical imaging technology. A camera captures images of the blade, and image processing algorithms calculate the distance between the back and cutting edge without any physical contact. This substitution eliminates the harmful mechanical contact that could damage the blade edge while maintaining measurement capability.
Solution Approach 2:
The patent creates a digital copy (image) of the blade and performs measurements on this copy rather than the physical blade itself. The image processing system extracts geometric information from the captured image, allowing measurement of blade wear without touching the actual blade, thus avoiding any potential damage.
2Productivity
If intermittent measurement methods are used for blade wear, then measurement frequency is reduced, but measurement accuracy decreases
Solution Approach 1:
The patent enables continuous or frequent measurement capability through automated image capture and processing. The system can acquire blade images at multiple time points and continuously track wear progression, providing ongoing measurement data without the limitations of intermittent methods. This continuous monitoring improves measurement accuracy while maintaining high productivity.
Solution Approach 2:
The measurement system is integrated into the cutting machine itself, with the camera and processing capabilities built-in. The system automatically captures images and calculates wear dimensions without requiring external measurement equipment or manual intervention, enabling frequent self-measurement that improves both accuracy and productivity.
3Reliability
If manual measurement and data reintegration is performed regularly, then blade wear tracking is maintained, but time consumption increases
Solution Approach 1:
The system automatically performs the complete measurement and data processing workflow without human intervention. The camera captures blade images, the processing system calculates wear dimensions, and the data is integrated into the cutting machine's control system automatically. This automation eliminates the time-consuming manual measurement and data reintegration processes while maintaining reliable wear tracking.
Solution Approach 2:
The system establishes an automated feedback loop where blade wear measurements are continuously obtained and fed back to the control system. This feedback mechanism automatically updates cutting parameters based on measured wear, eliminating the need for manual data reintegration and ensuring timely adjustments for maintaining cutting quality.
4Measurement precision
If filtered dimension calculation is used for wear measurement, then measurement accuracy improves, but processing complexity increases
Solution Approach 1:
The patent replaces complex physical measurement mechanisms with computational image processing. Instead of using complex mechanical measurement devices, the system uses software algorithms to analyze blade images and calculate filtered dimensions. This substitution achieves high measurement accuracy through digital processing while avoiding the mechanical complexity of precision measurement instruments.
Data Source
AI summary
A method for determining a dimension between the back and the cutting edge of a vibrating blade mounted on a cutting head includes successively of acquiring a digital image of the blade mounted on the cutting tool so a line corresponding to a cutting edge of the blade and a line corresponding to a back of the blade are visible in the image, determining on the digital image along a straight line perpendicular to the line corresponding to the cutting edge of the blade the pixels comprised between the line corresponding to the cutting edge of the blade and the line corresponding to the back of the blade, and calculating a filtered dimension between the back and the cutting edge of the blade from the number of pixels comprised between the line corresponding to the cutting edge of the blade and the line corresponding to the back of the blade.