A sensor calibration device and method of use thereof

Abstract

The application discloses a sensor calibration device and a use method thereof. The device comprises a base, a sliding mechanism, a clamping mechanism, a sensor and a screw micrometer. The sliding mechanism is installed on the base. The screw micrometer is installed on the side surface of one side of the sliding mechanism. The clamping mechanism is installed on the base through a vertical screw rod. The clamping mechanism can move up and down on the vertical screw rod. The sensor is installed on the clamping mechanism and above the sliding mechanism. The sensor calibration device can meet the continuous precision calibration of various different types of sensors in the full range and realize the value transmission in microns.

Description

Technical Field

[0001] This invention relates to the field of precision testing technology, and more specifically to a sensor calibration device and its usage method. Background Technology

[0002] In the field of geometric measurement, commonly used displacement sensors include inductive sensors, differential sensors, and other types. Before use, these sensors require linear calibration, i.e., accuracy calibration. Common gauge block calibration methods cannot achieve continuous calibration within the measurement range. Furthermore, for certain special calibration points, gauge blocks must be used in combination, inevitably introducing a certain amount of cumulative error, thus leading to calibration errors. Summary of the Invention

[0003] To address the shortcomings of the aforementioned technical solutions, the present invention aims to provide a sensor calibration device.

[0004] Another object of the present invention is to provide a method of using the above-described sensor calibration device.

[0005] The objective of this invention is achieved through the following technical solution.

[0006] A sensor calibration device includes a base, a sliding mechanism, a clamping mechanism, a sensor, and a micrometer. The sliding mechanism is mounted on the base, and the micrometer is mounted on one side of the sliding mechanism. The clamping mechanism is mounted on the base via a vertical screw and can move up and down on the vertical screw. The clamping mechanism is used to clamp the sensor, and the sensor is mounted on the clamping mechanism and located above the sliding mechanism.

[0007] The sensor has a built-in laser and a CCD photosensitive element. The laser beam is reflected onto the CCD photosensitive element after it encounters the object being measured.

[0008] The sliding mechanism includes a base and a slider. The base is mounted on the base, and the slider is mounted on the base. The base and the slider are inclined and fitted together. The micrometer is mounted on one side of the slider to control the feed rate.

[0009] The clamping mechanism drives the sensor to move up and down along the Z direction, and controls the feed amount through a micrometer screw gauge, converting the horizontal displacement into the Z-direction displacement.

[0010] In the above technical solution, a sliding track is provided on the upper surface of the base. The upper surface of the sliding track is a first inclined surface. The lower surface of the slider is provided with a sliding groove that matches the sliding track. The sliding track is embedded in the sliding groove. The lower surface of the groove wall of the sliding groove is a second inclined surface. The contact surfaces of the first inclined surface and the second inclined surface are in contact.

[0011] In the above technical solution, the lower surface of the base and the upper surface of the slider are both horizontal surfaces.

[0012] In the above technical solution, a limiting ring is installed on the vertical screw, the limiting ring is threadedly connected to the vertical screw, and the limiting ring is located below the clamping mechanism to limit the movement of the clamping mechanism on the vertical screw.

[0013] In the above technical solution, the outer surface of the limiting ring is knurled.

[0014] In the above technical solution, the clamping mechanism is threadedly connected to the vertical screw, and a sensor is installed at the front end of the clamping mechanism.

[0015] In the above technical solution, mounting holes for installing vertical screws and bases are provided on the base.

[0016] In the above technical solution, the sensor is a laser sensor.

[0017] The method of using the above-mentioned sensor calibration device includes the following steps:

[0018] Step 1: Install the sensor on the clamping mechanism. Adjust the position of the sensor on the vertical screw according to the sensor's range. After the sensor contacts the slider, continue to adjust its position until the physical zero point is found and mark it as the calibration zero point. Use a limit ring to limit the position of the sensor.

[0019] Step 2: Based on the accuracy of the sensor, select an appropriate micrometer and install it on the slider. Rotate the micrometer so that its feed amount is an integer multiple of the sensor's accuracy value, and set each fixed feed interval as a calibration point.

[0020] Step 3: Starting from the zero calibration point, rotate the micrometer screw gauge to feed it to the calibration point in both the positive and negative directions, and record the real-time displacement change of the sensor.

[0021] Step 4: Calculate the difference between the value at each calibration point and the change in sensor displacement, and use it as the error value for that calibration point. Calculate the fitting compensation formula based on all calibration points to complete the linear compensation of the sensor.

[0022] In the above technical solution, the sensor has a range of ±1mm and an accuracy of 5μm.

[0023] In the above technical solutions,

[0024] The advantages and beneficial effects of this invention are as follows:

[0025] 1. The main function of the device of the present invention is to calibrate the accuracy of the calibration points within the ±y range, thereby obtaining the linear error of the sensor. After correction, the sampling accuracy of the sensor can be effectively improved.

[0026] 2. The sensor calibration device of the present invention can meet the requirements of continuous accuracy calibration of various types of sensors across the entire range and realize the transfer of values ​​at the micrometer level.

[0027] 3. This invention, through the cooperation of the limiting ring, the vertical screw and the clamping mechanism, can drive the sensor to move up and down in the vertical direction (Z direction), and accurately control the feed amount through the micrometer screw, thereby realizing the linear error calibration of the sensor.

[0028] 4. The sensor calibration device of this invention is mainly used for accuracy calibration of sensors before use. This device can be freely matched according to the range and accuracy of the sensor being tested, meeting the accuracy calibration needs of sensors of different types, accuracies, and ranges. The micrometer combined with the sliding mechanism design can convert horizontal displacement into Z-axis (vertical) displacement, thereby achieving full-range, uninterrupted calibration of the sensor. Furthermore, it can plot a linear error curve based on the calibration results and perform error correction through software, meeting the sensor accuracy correction requirements. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of the sensor calibration device of the present invention;

[0030] Figure 2 This is a side view of the sliding mechanism of the present invention;

[0031] Figure 3 This is a partial structural schematic diagram of the present invention;

[0032] Figure 4 This is a schematic diagram illustrating the calibration principle of the laser sensor of the present invention.

[0033] in,

[0034] 1: Base, 2: Sliding mechanism, 2-1: Base, 2-2: Slider, 2-3: Sliding track, 2-4: Sliding groove, 3: Clamping mechanism, 4: Sensor, 5: Micrometer, 6: Vertical screw, 7: Limiting ring.

[0035] For those skilled in the art, other related figures can be obtained from the above figures without any creative effort. Detailed Implementation

[0036] The technical solution of the present invention will be further described below with reference to specific embodiments.

[0037] Example 1

[0038] like Figure 1-3 As shown, a sensor calibration device includes a base 1, a sliding mechanism 2, a clamping mechanism 3, a sensor 4, and a micrometer 5. The sliding mechanism 2 is mounted on the base 1, and the micrometer 5 is mounted on one side of the sliding mechanism 2. The clamping mechanism 3 is mounted on the base 1 via a vertical screw 6 and can move up and down on the vertical screw 6. The sensor 4 is mounted on the clamping mechanism 3 and is located above the sliding mechanism 2.

[0039] The sensor has a built-in laser and a CCD photosensitive element. The laser beam is reflected onto the CCD photosensitive element after it encounters the object being measured.

[0040] The sliding mechanism 2 includes a base 2-1 and a slider 2-2. The base 2-1 is mounted on the base 1, and the slider 2-2 is mounted above the base 2-1, allowing it to slide on the base 2-1. The micrometer 5 is mounted on one side of the slider 2-2. Specifically, a sliding track 2-3 with a trapezoidal vertical cross-section is provided on the upper surface of the base 2-1 (the upper base of the trapezoid is longer than the lower base; specifically, the trapezoid is an isosceles trapezoid). The upper surface of the sliding track 2-3 is a first inclined plane, and the lower surface of the slider 2-2 is provided with a surface matching the sliding track 2-3. The sliding groove 2-4 is embedded in the sliding track 2-3. The lower surface of the groove wall of the sliding groove 2-4 is a second inclined surface. The contact surfaces of the first inclined surface and the second inclined surface are in contact. The sliding groove 2-4 slides on the sliding track 2-3. The micrometer 5 is installed on the side of the slider 2-2, where the lowest point of the second inclined surface is located. The lower surface of the base 2-1 and the upper surface of the slider 2-2 are both horizontal. Through the above structural arrangement between the slider 2-2 and the base 2-1, the horizontal displacement of the micrometer 5 is converted into the vertical displacement of the slider 2-2 during the sliding process of the slider 2-2 on the base 2-1.

[0041] In this embodiment, the micrometer 5 is matched with the sensor 4 in terms of accuracy, with a commonly used accuracy range of 0.5 to 10 μm, or other ranges.

[0042] Example 2

[0043] like Figure 1-3As shown, based on Embodiment 1, a limiting ring 7 is installed on the vertical screw 6. The limiting ring 7 is threadedly connected to the vertical screw 6. The limiting ring 7 is located below the clamping mechanism 3 and is used to restrict the movement of the clamping mechanism 3 on the vertical screw 6. The outer surface of the limiting ring 7 is provided with knurling to facilitate manual screwing of the limiting ring 7 on the vertical screw 6.

[0044] Example 3

[0045] like Figure 1-3 As shown, based on embodiments 1 and 2, the clamping mechanism 3 is threadedly connected to the vertical screw 6, and a sensor 4 is installed at the front end of the clamping mechanism 3 so that the clamping mechanism 3 drives the sensor 4 to move up and down along the vertical screw 6.

[0046] The base 1 has mounting holes for mounting the vertical screw 6 and the base 2-1.

[0047] Example 4

[0048] like Figure 4 As shown, based on embodiments 1-3, in this embodiment, the sensor 4 is a laser sensor. Its principle is that a laser emits a beam of light, which is reflected onto the CCD photosensitive element after encountering the workpiece being measured. Changes in the size of the workpiece can be reflected as changes in the photosensitive area on the CCD, and the displacement can be calculated. In the figure, the horizontal line D represents the physical zero point of sensor 4, and y represents its positive and negative limit ranges.

[0049] Example 5

[0050] Based on Examples 1 to 3, in this example, the sensor 4 is a type of sensor such as a pen-type inductive sensor.

[0051] Example 6

[0052] The method of using the sensor calibration device described in Examples 1-5 includes the following steps:

[0053] Step 1: Install sensor 4 on clamping mechanism 3. Adjust the position of sensor 4 on vertical screw 6 according to the range of sensor 4. After sensor 4 contacts slider, continue to adjust its position until physical zero position is found and marked as calibration zero position. Limit the position of sensor 4 with limit ring 7.

[0054] Step 2: Based on the accuracy of sensor 4, select an appropriate micrometer 5 and install it on slider 2-2. Rotate the micrometer 5 so that its feed amount is an integer multiple of the accuracy value of sensor 4, and set each fixed feed interval as a calibration point.

[0055] Step 3: Starting from the zero calibration point, rotate the micrometer screw 5 to feed it to the calibration point in the positive and negative directions respectively, and record the real-time displacement change of the sensor 4.

[0056] Step 4: Calculate the difference between the value at each calibration point and the displacement change of sensor 4, and use it as the error value for that calibration point. Calculate the fitting compensation formula based on all calibration points to complete the linear compensation of sensor 4.

[0057] Taking a sensor with a range of ±1mm and an accuracy of 5μm as an example, its calibration results can be recorded in the following table:

[0058]

[0059] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0060] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0061] The present invention has been described above by way of example. It should be noted that any simple modifications, alterations or other equivalent substitutions that can be made by those skilled in the art without creative effort without departing from the core of the present invention fall within the protection scope of the present invention.

Claims

1. A sensor calibration device, characterized in that, The device includes a base, a sliding mechanism, a clamping mechanism, a sensor, and a micrometer. The sliding mechanism is mounted on the base, and the micrometer is mounted on one side of the sliding mechanism. The clamping mechanism is mounted on the base via a vertical screw and can move up and down on the vertical screw. The clamping mechanism is used to clamp the sensor, which is mounted on the clamping mechanism and located above the sliding mechanism. The sensor has a built-in laser and a CCD photosensitive element. The laser beam is reflected onto the CCD photosensitive element after it encounters the object being measured. The sliding mechanism includes a base and a slider. The base is mounted on the base, and the slider is mounted on the base. The base and the slider are inclined and fitted together. The micrometer is mounted on one side of the slider to control the feed rate. The clamping mechanism drives the sensor to move up and down along the Z direction, and controls the feed amount through the micrometer screw gauge to convert the horizontal displacement into the Z direction displacement. A sliding track is provided on the upper surface of the base. The upper surface of the sliding track is a first inclined surface. The lower surface of the slider is provided with a sliding groove that matches the sliding track. The sliding track is embedded in the sliding groove. The lower surface of the groove wall of the sliding groove is a second inclined surface. The contact surfaces of the first inclined surface and the second inclined surface are in contact. The lower surface of the base is a horizontal plane; the upper surface of the slider is a horizontal plane.

2. The sensor calibration device according to claim 1, characterized in that, A limiting ring is installed on the vertical screw, and the limiting ring is located below the clamping mechanism to restrict the movement of the clamping mechanism on the vertical screw.

3. The sensor calibration device according to claim 2, characterized in that, The limiting ring is threadedly connected to the vertical screw, and moves up and down on the vertical screw.

4. The sensor calibration device according to claim 3, characterized in that, The outer surface of the limiting ring is knurled.

5. The sensor calibration device according to claim 4, characterized in that, The clamping mechanism is threadedly connected to the vertical screw.

6. The sensor calibration device according to claim 5, characterized in that, A sensor is installed at the front end of the clamping mechanism.

7. The sensor calibration device according to claim 6, characterized in that, The base has mounting holes for installing vertical screws.

8. The sensor calibration device according to claim 7, characterized in that, The base has mounting holes for mounting bases.

9. The sensor calibration device according to claim 8, characterized in that, The sensor is a laser sensor.

10. The method of using the sensor calibration device as described in any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Install the sensor on the clamping mechanism. Adjust the position of the sensor on the vertical screw according to the sensor's range. After the sensor contacts the slider, continue to adjust its position until the physical zero point is found and mark it as the calibration zero point. Use a limit ring to limit the position of the sensor. Step 2: Based on the accuracy of the sensor, select an appropriate micrometer and install it on the slider. Rotate the micrometer so that its feed amount is an integer multiple of the sensor's accuracy value, and set each fixed feed interval as a calibration point. Step 3: Starting from the zero calibration point, rotate the micrometer screw gauge to feed it to the calibration point in both the positive and negative directions, and record the real-time displacement change of the sensor. Step 4: Calculate the difference between the value at each calibration point and the change in sensor displacement, and use it as the error value for that calibration point. Calculate the fitting compensation formula based on all calibration points to complete the linear compensation of the sensor.

11. The method of use according to claim 10, characterized in that, The sensor has a range of ±1 mm and an accuracy of 5 μm.

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