Aligned Sensor Module Housing for Tolerance-Compensated Mounting
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Solution Overview
Problem
Existing sensor modules, particularly optoelectronic sensors like laser scanners, face alignment issues due to manufacturing tolerances, requiring manual adjustment and additional mounts, which are costly and prone to misalignment during operation.
Innovation Solution
A sensor module with a first outer wall having a three-dimensional contour that compensates for individual detection direction and height deviations, ensuring automatic alignment during installation by integrating an intermediate piece with a customized shape to match manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and additional mounts are used to compensate for manufacturing tolerances, then alignment precision can be improved, but device complexity and installation cost increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-compensating for manufacturing tolerances during the sensor module production phase. Individual compensation values are determined for each sensor module based on its specific deviations, and these values are stored in memory before the module is installed. This eliminates the need for complex manual alignment mounts during installation, as the compensation is already built into the module itself.
Solution Approach 2:
The sensor module performs self-alignment through automated compensation. The control unit automatically retrieves pre-calculated compensation values from memory and applies them to correct detection direction and height deviations. This self-service mechanism eliminates the need for external alignment mounts and manual adjustment procedures, reducing both device complexity and installation requirements.
2Measurement precision
If manual alignment procedures are implemented during installation, then detection precision can be improved, but installation time and effort increase
Solution Approach 1:
The patent performs preliminary compensation calculations and stores correction values in memory during sensor module manufacturing. This preliminary action transfers the alignment work from the installation phase to the production phase, allowing rapid deployment during installation without time-consuming manual alignment procedures while maintaining high detection precision through automated compensation.
Solution Approach 2:
The patent replaces manual mechanical alignment procedures with an automated electronic compensation system. Instead of physically adjusting mounts and sensors during installation, the system uses pre-calculated digital compensation values stored in memory that are automatically applied by the control unit, substituting mechanical adjustment with electronic correction to reduce installation time.
3Adaptability or versatility
If adjustable mounts are used to enable alignment, then alignment flexibility is improved, but reliability decreases due to potential loss of alignment during operation
Solution Approach 1:
The sensor module achieves self-alignment through automated compensation using pre-stored values in memory. The control unit automatically applies these compensation values to maintain correct detection direction and height without requiring adjustable mounts. This eliminates the risk of alignment loss during operation while maintaining the flexibility needed to compensate for manufacturing tolerances, as the compensation is automatically maintained throughout the module's operational life.
Data Source
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AI summary
A sensor module (10) is specified for a sensor, comprising a sensor unit with a detection direction and detection height, and a module housing (36) with at least one first outer wall (42) for mounting on a flat base (44), thereby defining the orientation and height position of the module housing (36) and thus the detection direction and detection height of the sensor unit. The first outer wall (42) has a three-dimensional contour adapted to the individual detection direction and/or detection height of the sensor unit, and this three-dimensional contour compensates for tolerances of the sensor unit in detection direction and/or detection height when the first outer wall (42) is mounted on a flat base (44).