Angle Measurement System Using Wobbling Transparent Modulator
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Solution Overview
Problem
Existing angle measurement systems for rotating shafts are sensitive to mechanical tolerances and degrees of freedom, requiring complex adjustments and precise positioning of components, which increases costs and reduces compactness.
Innovation Solution
An angle measuring system that uses a wobbling transparent modulator to determine the angle of rotation independently of shaft movements, with a simple evaluation logic that calculates the angle from light point positions on a receiver, allowing for self-calibration and continuous error minimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If precise positioning and adjustment mechanisms are used to improve measurement accuracy, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The evaluation unit automatically compensates for mechanical tolerances and positioning errors through software algorithms. The system performs self-calibration by detecting the actual positions of the light transmitter and detector array, calculating correction values, and applying these corrections to subsequent measurements without requiring manual adjustment mechanisms.
Solution Approach 2:
The patent replaces mechanical adjustment mechanisms with an optical-electronic measurement system combined with software-based compensation. Instead of using complex mechanical positioning devices to achieve precise alignment, the system uses a camera to detect light positions and computational algorithms to correct for positioning errors, thereby eliminating the need for complex mechanical adjustment mechanisms.
2Measurement precision
If complex adjustment mechanisms are used to improve measurement accuracy, then measurement precision is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The system performs automatic self-calibration during operation. The evaluation unit detects the actual positions of sensor components, calculates correction values based on these detected positions, and applies corrections automatically. This eliminates the need for complex manual adjustment procedures during assembly and manufacturing.
Solution Approach 2:
The system changes the approach from adjusting physical parameters (mechanical positioning) to adjusting computational parameters (correction values in software). By storing and applying correction values digitally, the system achieves high measurement precision without requiring precise mechanical assembly, thereby simplifying manufacturing and reducing assembly time.
3Measurement precision
If symmetrical arrangement is used to compensate for eccentricity, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the need for symmetrical mechanical arrangements with an optical detection system and computational compensation. Instead of using multiple symmetrically arranged reading heads to compensate for code disk eccentricity, the system uses a single camera to detect light positions and software algorithms to calculate and correct for eccentricity effects, thereby achieving the same precision without the mechanical complexity.
Solution Approach 2:
The evaluation unit automatically detects and compensates for eccentricity through software. By detecting the actual positions of light spots and calculating correction values, the system self-corrects for eccentricity without requiring symmetrical mechanical arrangements, thereby simplifying the device structure while maintaining measurement precision.
4Measurement precision
If active alignment mechanisms are used to improve signal quality, then measurement precision is improved, but compactness is reduced
Solution Approach 1:
The patent replaces active mechanical alignment mechanisms with an optical detection system and software-based signal processing. Instead of using additional mechanisms to actively align sensor components, the system uses a camera to detect light positions and computational methods to maintain signal quality, thereby achieving high precision without increasing the sensor's physical size.
Solution Approach 2:
The system performs automatic calibration and maintains optimal signal quality through software algorithms that detect and correct for positioning errors. This self-service approach eliminates the need for additional active alignment mechanisms, thereby maintaining compact sensor design while ensuring high signal quality and measurement precision.
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
The system provides accurate and robust angle measurement independent of mechanical tolerances and degrees of freedom, enabling simple, cost-effective, and compact design with continuous self-calibration and reduced measurement errors.
Implementation Method 1
a transparent modulator (2) for modulating the emitted light beam (1a) passing through the modulator (2)
Implementation Method 2
a receiver (3) for receiving the modulated light beam (1a)
Data Source
Figure 1~2
Figure 3.1~3.3
Figure 4~6
AI summary
PROBLEM TO BE SOLVED: To provide an inexpensive angle measuring device for determining a rotational angle of a rotary shaft.SOLUTION: A device 10 comprises: a light source; a transparent modulator 2 which is mounted to a shaft W such that the normal line thereof forms a nonzero angle α with the rotation axis of the shaft and which lets the light beam from the light source pass therethrough for modulation; at least one light receiver 3 which detects a light spot Pi moving on its own surface during rotation of the modulator and outputs a corresponding light receiver signal, and which comprises a photosensitive surface to detect an incident light spot in a positionally resolved manner; and an evaluation unit which evaluates the light receiver signal to determine the rotational angle φ, the evaluation unit being configured such that the rotational angle of the shaft is determined from the position of the light spot on the light receiver. The transparent modulator is composed of a plane-parallel plate having a predetermined thickness, a predetermined diameter, and a predetermined relative refractive index n2. The light receiver detects the incident light spot in a two-dimensionally positionally resolved manner, the light spot ideally drawing a circular trajectory on the light receiver.SELECTED DRAWING: Figure 1