Laser scanning systems and methods for measuring extruded ceramic logs

• US 9,662,825 B2
• Filed: 01/09/2014
• Issued: 05/30/2017
• Est. Priority Date: 05/12/2010
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Breuer, Klaus, Deeter, Lee Edgar, Marlowe, James Monroe, Susch, Nicholas Leon
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US14/151,047
• Publication Number:
  US 20140124970A1
• Time in Patent Office: 1,237 Days
• Field of Search: 264 401, 264630, 264631, 264632, 264633, 264638, 264652, 264437, 2641761-1771, 26417712, 356601, 356612, 425113
• CPC Class Codes: B28B 17/0072 Product control or inspection
• CPC Class Codes: B29C 2948/92019 Pressure
• CPC Class Codes: B29C 2948/92514 Pressure
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/286 Raw material dosing
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29K 2309/02 Ceramics
• CPC Class Codes: B29K 2709/02 Ceramics
• CPC Class Codes: G01B 11/245 using a plurality of fixed, simultaneously operating transducers G01B11/2408 - G01B11/2425, G01B11/255 take precedence
• CPC Class Codes: G01B 11/2518 Projection by scanning of the object

Abstract

Laser scanning systems and methods are disclosed herein that can provide quick and efficient measurement of extruded ceramic logs, particularly related to log shape, during manufacture. Two two-dimensional laser scans from respective laser scanners are performed and the resulting laser scan data is combined to form a three-dimensional surface shape measurement of the ceramic log. The systems and methods disclosed herein enable a non-contact measurement of the extruded ceramic log, which reduces the risk of physically damaging the log. The measurement results can be used to adjust the extrusion process of the extruder that forms the extruded ceramic logs.

Claims

1. An in situ system, in a ceramic log extrusion manufacturing system, for measuring a surface shape of an extruded ceramic log supported by a tray and having an axis and an outer surface, the in situ system comprising:

a conveyor configured to support and convey the tray and the log supported thereby in a conveyor direction that is perpendicular to the log axis;

a support structure arranged within the ceramic log manufacturing system;

a mount attached to the support structure so as to reside over the conveyor and configured to be movable in a direction of the ceramic log axis;

first and second laser scanners attached to the mount and having respective first and second scan paths that intersect the log outer surface at substantially right angles to the log axis; and

a controller configured to stop the conveyor and move the mount to different ceramic log axial positions, to activate the first and second laser scanners at the different axial positions to perform respective first and second laser scans to create a set of two-dimensional surface shape measurements, and to combine the set of two-dimensional surface shape measurements to form a three-dimensional surface shape measurement.

2. The system according to claim 1, wherein the controller includes instructions embodied in a computer readable medium that cause the controller to calculate from the three-dimensional surface shape measurement at least one of an amount of bow in the ceramic log and a log length of the ceramic log.

3. The system according to claim 2, wherein the instructions embodied in the computer readable medium further cause the computer to compare at least one of the amount of bow and log length to at least one of a bow limit and a log-length limit.

4. The system of claim 1, wherein the first and second scan paths define a measurement position, and wherein the system further comprises a lifting mechanism configured to lift the tray and the ceramic log supported thereby so that ceramic log is placed at the measurement position.

5. The system of claim 1, wherein the first and second scan paths define a measurement position such that the ceramic log need not be removed from the conveyor when performing the first and second laser scans.