Workpiece Inspection Misalignment Correction and Parallel Processing
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Solution Overview
Problem
Existing workpiece inspection apparatuses face challenges in achieving high-accuracy inspections due to misalignment of the workpiece's symmetry axis with the rotary axis, leading to increased cycle time and reduced efficiency in inspecting rotationally symmetric workpieces.
Innovation Solution
The method involves capturing images of the workpiece at a pre-alignment position, detecting and correcting misalignment, and then inspecting the workpiece at an inspection position, allowing for parallel processing of subsequent workpieces to reduce cycle time and improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the workpiece is held and rotated for inspection, then the inspection can be performed, but misalignment between the symmetry axis and rotary axis reduces measurement precision
Solution Approach 1:
The system performs preliminary alignment by capturing images at a pre-alignment position, detecting misalignment, and correcting the workpiece position before the actual inspection. This preliminary action eliminates alignment errors that would otherwise degrade measurement precision during inspection.
Solution Approach 2:
The patent replaces manual or mechanical alignment adjustment with an automated optical detection and control system. Images captured by the imaging device are processed to detect misalignment, and the holding table is automatically repositioned based on detected errors, substituting mechanical alignment operations with automated optical-mechanical integration.
2Measurement precision
If workpieces are inspected one by one in succession, then inspection accuracy can be maintained, but the cycle time increases reducing productivity
Solution Approach 1:
The system implements continuous inspection by eliminating idle time between workpieces. The holding table automatically repositions the next workpiece into position while the current workpiece is being inspected, and the imaging device continuously captures images. This continuous operation maintains inspection accuracy while significantly reducing cycle time and increasing productivity.
Solution Approach 2:
The system performs preliminary positioning and alignment of the next workpiece before the current inspection is complete. This preliminary action ensures that when the current workpiece finishes inspection, the next workpiece is already ready for immediate inspection, maintaining continuous operation and high productivity.
3Productivity
If misalignment is not corrected, then cycle time is reduced, but inspection accuracy deteriorates
Solution Approach 1:
The patent replaces time-consuming manual alignment adjustment with automated optical detection and motor-driven repositioning. The imaging device quickly detects misalignment, and the holding table automatically corrects position based on detected errors, maintaining high inspection speed while ensuring accuracy.
Solution Approach 2:
The system implements a feedback loop where the imaging device continuously monitors workpiece alignment, detects misalignment errors, and feeds this information back to the holding table control system. The holding table then automatically adjusts the workpiece position to eliminate misalignment, ensuring inspection accuracy without manual intervention and maintaining high productivity.
Data Source
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AI summary
A workpiece having an outer peripheral portion rotationally symmetric about a symmetry axis can be inspected with high-accuracy while reducing cycle time of the inspection. In an inspection for each of the workpieces, on the basis of the image of the workpiece acquired by executing a first step of capturing an image of the workpiece while holding the workpiece at a pre-alignment position using a holding table and rotating the workpiece about a rotary axis, a position of the workpiece at the holding table is corrected so as to eliminate misalignment of the symmetry axis with respect to the rotary axis. Thereafter, on the basis of the image acquired by executing a fifth step of capturing an image of the workpiece while rotating the workpiece about the rotary axis at an inspection position, the workpiece is inspected. In the inspection of the workpiece, the fifth step for a previous workpiece of two consecutive workpieces and the first step for a next workpiece are executed in parallel with each other.