Alignment Receiver for Sensor Device Beam Positioning
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Solution Overview
Problem
Existing methods for aligning sensor devices, such as light curtains, face inaccuracies due to tolerances in alignment lasers and mismatched radiation characteristics, making precise alignment complex and prone to loss when the alignment laser is removed.
Innovation Solution
A method using an alignment receiver with a larger opening angle than the standard receiver, positioned in front of the receiver unit, to directly measure the alignment of light beams, providing a quantitative and reproducible alignment process by receiving light beams and displaying alignment quality through a display unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an alignment laser is used to align the transmitter unit and receiver unit, then the alignment process can be performed, but the beam axes of the light curtain itself are not aligned due to tolerances in the fastening position and mismatched radiation characteristics
Solution Approach 1:
An alignment receiver is introduced as an intermediary device between the transmitter unit and the original receiver unit. This alignment receiver has a larger opening angle than the standard receiver, allowing it to capture light beams even when the transmitter and receiver are not perfectly aligned. The alignment receiver provides direct feedback about the actual alignment state of the light curtain beam axes, serving as a mediator that bridges the gap between the alignment laser's indirect indication and the actual alignment requirement.
2Reliability
If the alignment laser emits narrow directional beams, then the radiation characteristics are well-defined, but the point of impact is difficult to see at greater distances and exact positioning is required
Solution Approach 1:
The opening angle parameter of the receiver is changed to create the alignment receiver with a larger opening angle than the standard receiver. This parameter change allows the alignment receiver to capture light beams over a wider angular range, making the alignment process more tolerant to positioning errors and easier to perform at greater distances while maintaining reliable beam detection.
3Ease of operation
If the alignment laser is mounted on one unit for adjustment, then the alignment can be performed, but the alignment position is lost when the alignment laser is removed
Solution Approach 1:
The alignment receiver creates a functional copy of the alignment verification capability. Instead of relying on the physical presence of the alignment laser mounted on one unit, the alignment receiver provides a standalone verification device that can be positioned at the receiver unit and directly measure the alignment quality. This copying approach allows the alignment information to be preserved and verified independently of the alignment laser's physical mounting position.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and reproducible alignment of sensor devices with reduced effort, as the alignment receiver captures light beams even when the units are misaligned, offering a direct and accurate measure of alignment quality, and allows for continuous alignment monitoring.
Implementation Method 1
an alignment receiver which is placed on the receiver unit in front of the receiver, has a larger opening angle than the receiver and receives the light beams emitted by the transmitter
Data Source
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AI summary
The invention relates to a method for aligning a sensor device (1) comprising a transmitter unit (2) with at least one light beam (3) emitting transmitter (4) and a receiver unit (5) with at least one receiver (6) associated with the transmitter (4), which receives the light beams (3) from the transmitter (4) during the sensor device's (1) operating mode. To align the transmitter unit (2), an alignment receiver (8) is placed on the receiver unit (5) in front of the receiver (6), which has a larger opening angle than the receiver (6). The alignment receiver (8) receives the light beams (3) emitted by the transmitter (4). Depending on the amount of light from the light beams (3) received by the alignment receiver (8), a display unit (10) provides an indication.