Actuator Alignment Stage for Multi-Test Positioning Accuracy

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Solution Overview

Problem

Existing actuator alignment systems face challenges in maintaining proper alignment during multiple tests, leading to defects and damage due to loose mechanical couplings and repeated repositioning, which increases overall test time and reduces efficiency.

Innovation Solution

An integrated actuator test system with a control unit, support socket, alignment stage, and transporting unit that allows for quick alignment and smooth performance of multiple tests by using a combination of stages and a camera for precise positioning and measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If actuators are transported between test positions, then multiple tests can be performed, but alignment is disturbed and test quality deteriorates

Engineering Contradiction:

Improvetest throughputVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system divides the test process into discrete test positions (first test position, second test position) with dedicated test boards, allowing actuators to be sequentially tested at each position without requiring realignment during transport between positions

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The actuator support socket and alignment stage form a universal platform that can accommodate multiple different test boards at different positions, enabling the same alignment mechanism to serve multiple test functions without compromising alignment precision

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If mechanical coupling is used for alignment, then alignment can be achieved, but coupling becomes loose over time causing defects

Engineering Contradiction:

Improvealignment capabilityVSAvoidalignment stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system replaces traditional mechanical coupling alignment with an optical alignment system using alignment cameras and image processing to detect and correct alignment deviations, eliminating the loosening problem inherent in mechanical couplings

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If realignment is performed at each test position, then alignment can be maintained, but test time increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidtest cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The alignment stage performs preliminary alignment of the actuator at each test position before the actual test begins, using alignment cameras to detect positional deviations and automatically adjusting the actuator position to eliminate the need for time-consuming realignment during testing

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12578380B2Integrated actuator test system and method for operating the same

Publication Date: 2026.03.17 PAMTEK CORP

AI summary

An integrated actuator test system for performing the first test and the second test and a method for operating the system. The test system includes a control unit controlling an operation of the test system; a support socket supporting the actuator; an alignment stage supporting the support socket and determining a direction of the support socket; and a transporting unit transporting the alignment stage to perform the second test after performing the first test.