Wire Curvature Detection Using Camera Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for detecting wire curvature are limited in their ability to accurately measure wires of different thicknesses and surface structures, often requiring adjustments and providing unreliable readings due to their reliance on specific geometries and opto-electronic scanning methods that are prone to errors from irregularities in the material.
Innovation Solution
A device comprising a camera system and data evaluation unit that captures image data of the wire, allowing for optical detection and determination of wire curvature, with a wire guide that adapts to different wire cross-sections and uses multiple cameras positioned at angles to capture the wire's boundaries in multiple planes, enabling curvature detection in three spatial dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If opto-electronic scanning with photodiodes is used to detect wire curvature, then the position of the material can be deduced from light quantity fluctuations, but the device requires re-setup when material changes and is disrupted by surface irregularities
Solution Approach 1:
The patent replaces the mechanical/opto-electronic scanning system with a camera-based optical imaging system. Instead of using photodiodes to detect light quantity fluctuations, the invention uses a camera to capture images of the wire, which are then processed to determine curvature. This substitution eliminates the need for precise mechanical alignment and makes the system adaptable to different wire geometries and surface structures.
Solution Approach 2:
The patent creates an optical copy (image) of the wire using a camera system. The camera captures the wire's position and curvature information in the form of image data, which is then analyzed by evaluation units. This copying approach allows the system to measure various wire types without physical contact or adjustment, as the measurement is based on the captured image rather than direct optical scanning.
2Measurement precision
If thickness measuring devices are used to measure wire dimensions, then the wire thickness can be measured, but the device is only suitable for specific geometries and cannot detect curvature
Solution Approach 1:
The patent implements a universal measurement system using a camera that can perform multiple functions: measuring wire thickness, detecting wire curvature, and determining wire position. The same camera system and image evaluation units that measure dimensions can also analyze the wire's spatial configuration and curvature by processing the captured images, eliminating the need for separate specialized devices.
3Measurement precision
If multiple measurements from different directions are taken to determine wire curvature, then curvature data can be obtained, but the method is unsuitable for long wires that cannot be easily placed on a rotatable table
Solution Approach 1:
The patent transitions from a one-dimensional scanning approach to a two-dimensional imaging approach. Instead of scanning the wire from one direction and rotating the table to capture multiple angles, the camera captures the wire's position and curvature information in a single two-dimensional image. The image evaluation units then extract curvature data from this planar view, making the system suitable for long wires that cannot be rotated or repositioned.
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
The solution provides a flexible and accurate method for detecting wire curvature, reducing measurement errors and allowing for the detection of wires with varying diameters and structures without the need for frequent adjustments, thereby improving the precision and reliability of wire straightening processes.
Implementation Method 1
a camera system (4) comprising at least one camera (4), which is positioned and dimensioned in such a way that it can capture a wire (2) guided in the wire guide (3) and its boundary perpendicular to a longitudinal axis (21) of the wire (2) as image data
Data Source
Figure 1~3c
Figure 4~5b
Figure 6a~6b
AI summary
A device for detecting wire curvature (1) comprises a wire guide (3), a camera system, and a data evaluation unit (5). The camera system includes at least one camera (4) and is positioned and dimensioned such that it can capture image data of a wire (2) guided in the wire guide (3) and its boundaries (22a, 22b) perpendicular to a longitudinal axis (21) of the wire. The data evaluation unit (5) can receive the image data from the camera system and determine the wire curvature from it.