Angle-Resolved Stray Light Sensor for Automatic Workpiece Positioning
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Solution Overview
Problem
Existing methods for non-contact surface assessment and position detection of workpieces, such as angle-resolved scattered light measurement technology, do not automatically identify the workpiece or its correct position within a clamping device, leading to potential errors in clamping and surface quality measurement.
Innovation Solution
An optical sensor using angle-resolved scattered light measurement technology scans the workpiece's surface for characteristic features, compares the measured intensity distribution with a calibrated pattern curve, and generates an error signal if the workpiece is incorrectly clamped, allowing for automatic identification and position detection, using statistical parameters like M for surface quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or automatic handling systems are used to clamp workpieces, then productivity is improved, but the risk of incorrect positioning and clamping errors increases
Solution Approach 1:
The optical sensor performs preliminary detection of the workpiece position and characteristics before the actual surface measurement takes place. The system scans for characteristic features and determines the workpiece position in advance, allowing correction or rejection of incorrectly positioned workpieces before they compromise measurement accuracy.
Solution Approach 2:
The system continuously monitors the workpiece position during the measurement process using optical detection. When deviations from the correct position are detected, the system generates error signals that can trigger corrective actions or reject the measurement, ensuring only properly positioned workpieces are measured.
2Reliability
If the optical sensor scans for characteristic features to detect workpiece position, then measurement reliability is improved, but the inspection time increases
Solution Approach 1:
The optical sensor serves multiple functions: it detects workpiece position, identifies characteristic features, and performs surface quality measurement. By combining these functions into a single sensor system, the patent avoids the time penalty of separate detection and measurement devices, maintaining high productivity while improving reliability.
Solution Approach 2:
The optical scanning and surface measurement operations are performed continuously in an integrated manner. The sensor continuously scans for characteristic features while simultaneously measuring surface properties, eliminating idle time between detection and measurement phases.
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 100% automatic control in production by reliably identifying the workpiece and its correct position, reducing systematic errors and improving surface quality measurement accuracy.
Implementation Method 1
an optical sensor emits a beam of rays with a defined intensity distribution onto the surface of a workpiece to be assessed and illuminates a measuring spot, and the reflected intensity of the radiation is measured
Implementation Method 2
the reflected intensity of the radiation is measured using a line sensor is detected with a discrete number of photodetectors in a defined angular range. The angular distribution of the surface of a finely machined surface is measured using backscattered light.
Data Source
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AI summary
A method and device for the non-contact assessment of the surface quality using angle-resolved scattered light measurement technology comprises an optical sensor (10). A characteristic value profile is determined from the measured reflected scattered light distribution during one rotation of the workpiece (30). This profile is then compared with a sample profile measured during a calibration process. If the characteristic value profile and the sample profile do not match, an error signal is generated.