Rotating Wheel Optical Inspection for Full-Circumference Defect Detection
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Solution Overview
Problem
Current wheel measurement solutions fail to provide accurate measurements for surface profiles and defects such as flats, out-of-roundness, gouges, and cracks, which can impact wheel operability.
Innovation Solution
An optical evaluation method using ultra-high speed smart cameras and multiple illumination techniques to capture and stitch partial circumference data, enabling full circumference analysis of wheel attributes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current wheel measurement solutions are used, then basic wheel attributes can be measured, but surface profile and defect measurements are insufficient
Solution Approach 1:
The wheel circumference is divided into multiple segments, with different illumination techniques applied to different segments. Laser line illumination captures cross-sectional profile data, while diffuse grazing illumination captures surface defect data. This segmentation allows each technique to optimize for its specific measurement type, resolving the contradiction between profile accuracy and defect detection reliability.
Solution Approach 2:
The system merges multiple illumination techniques (laser line and diffuse grazing) and multiple imaging modes into a single integrated measurement system. By combining the profile measurement capability with defect detection capability in one system, the patent achieves both high measurement precision and high reliability simultaneously.
2Measurement precision
If multiple illumination techniques are used to improve measurement accuracy, then defect detection improves, but system complexity increases
Solution Approach 1:
The illumination system is designed to be dynamic and adaptive, switching between laser line illumination and diffuse grazing illumination based on the measurement requirements. The system can activate only the necessary illumination technique for each measurement phase, reducing overall complexity while maintaining high measurement precision when needed.
Solution Approach 2:
The imaging system is designed with multi-functionality, using the same camera platform for both profile measurement and defect detection. This universal approach reduces device complexity by avoiding separate dedicated systems for each function, while still achieving high measurement accuracy through appropriate illumination selection.
3Measurement precision
If full circumference imaging is performed at high resolution, then defect coverage improves, but imaging speed decreases
Solution Approach 1:
The system applies partial action by using diffuse grazing illumination selectively only in regions where surface defects are likely to occur, rather than uniformly across the entire wheel circumference. This allows high-resolution imaging focused on critical areas, maintaining defect detection coverage while improving imaging speed by reducing the total number of high-resolution images required.
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
Accurately measures wheel defects and attributes, ensuring safe operation by detecting flaws like flats, out-of-roundness, and cracks with high resolution and coverage.
Implementation Method 1
The evaluation utilizes information acquired by radiation reflecting off of one or more regions of the rotating wheel
Implementation Method 2
obtaining image data for the wheel as it moves along the path
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
Evaluation of a rotating wheel is described. The evaluation utilizes information acquired by radiation reflecting off of one or more regions of the rotating wheel. An imaging device can acquire image data which is processed to evaluate the wheel. The radiation can comprise diffuse and/or coherent radiation. Image data for substantially an entire circumference of the wheel can be used in the evaluation.