Automated Bobbin-Baselayer Inspection System

A fast and precise measurement system is needed for production line testing of bobbin baselayers and wound bobbins. This system should also support investigations to establish the acceptance criteria. The video metrology machine proposed for Phase II will achieve rapid image acquisition by taking a sequence of video frames as the bobbin is rotated and translated through the field of view. The laser light source will pulsed in synchronism with the bobbin rotation to capture images at selected angular positions about the bobbin. Post processing of the data will re-sequence the frames into end-to-end axial profiles. The Phase I program will compare two image acquisition concepts: A collimated laser beam is interrupted by the bobbin profile producing a silhouette on the detector array of a video camera. A sheet of laser light produces an illuminated line on the bobbin surface. The video camera captures the surface shape at this slice by viewing at an angle between the surface and the light sheet. Images of actual bobbin baselayers and windings will be acquired with the two configurations and evaluated as a basis for design of a Phase II high-speed precision inspection system. Anticipated Benefits/Potential Applications - Recording the surface configuration of bobbin baselayers and windings can create a valuable data base for winding studies, statistical process control and failure analysis. On-the-fly image acquisition and off-line processing of mosaic profiles will have applicability in other production and research programs.