Wear Measurement System Using 3D Point Cloud Overlay
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Solution Overview
Problem
Conventional wear measurement techniques for earth-working machines are time-consuming and inaccurate, leading to incorrect predictions of component life, resulting in premature or delayed replacement, and require the machine to be taken out of service for measurement.
Innovation Solution
A wear measurement system using an imaging device to obtain two-dimensional images, generating a three-dimensional point cloud, overlaying a computer model, and determining wear by analyzing image distances between reference points, allowing for accurate wear assessment without removing the machine from service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurements of component dimensions are used, then the measurement process is simple, but the measurements are time-consuming and inaccurate
Solution Approach 1:
The patent replaces manual mechanical measurement tools with an optical imaging system that captures images of the component and automatically processes them to extract dimensional data. The imaging device captures visual information, and the processor automatically measures component dimensions by analyzing the captured images, eliminating the need for manual measurement tools and operations.
Solution Approach 2:
The patent creates a digital copy of the component through imaging that can be processed and measured without physically touching or manipulating the actual component. The captured images serve as digital replicas that can be analyzed repeatedly and accurately without additional time loss from repeated physical measurements.
2Productivity
If conventional measurement methods are used, then the equipment is simple, but the machine must be taken out of service for measurement
Solution Approach 1:
The measurement system allows the machine to continue operating while measurements are being taken. The imaging device can capture images of moving or operating components, and the processor can analyze these images without requiring the machine to stop, thereby maintaining continuous productive operation.
Solution Approach 2:
The patent replaces physical contact-based measurement methods that require machine shutdown with non-contact optical imaging that can perform measurements during normal operation, eliminating downtime while maintaining measurement capability.
3Reliability
If manual measurement and comparison against specified dimensions is performed, then the process is straightforward, but incorrect predictions regarding remaining life result
Solution Approach 1:
The patent replaces error-prone manual measurement and comparison processes with automated optical imaging and digital image processing. The system automatically captures component images, processes them to extract precise dimensional data, and compares measurements against specified dimensions, eliminating human error in reading, recording, and comparing measurements.
Solution Approach 2:
The system provides automated feedback by comparing measured dimensions against specified dimensions and generating predictions about component remaining life. This feedback loop enables continuous monitoring and accurate prediction of component condition without manual intervention errors.
Data Source
AI summary
A wear measurement system for a component is disclosed. The wear measurement system may include an imaging device configured to obtain a plurality of two-dimensional images of the component. The wear measurement system may also include a controller. The controller may be configured to generate a three-dimensional point cloud representing the component based on the two-dimensional images. The controller may also be configured to overlay a computer model of the component on the three-dimensional point cloud. Further, the controller may be configured to project the computer model on the two-dimensional images. The controller may also be configured to select at least two reference points appearing in each of a subset of images selected from the two-dimensional images. The controller may be configured to determine locations of the two reference points in the three-dimensional point cloud, determine an image distance between the locations, and determine an amount of wear based on the image distance.