Borescope Calibration Device Using Stepped Reference Surfaces
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Solution Overview
Problem
Borescopes lack a standardized calibration method for ensuring measurement accuracy, which is crucial for various industrial and medical applications, as they typically do not come with certification of measurement accuracy and require a reliable on-site calibration solution.
Innovation Solution
A portable borescope calibration device featuring a base with planar and stepped surfaces, a movable fixture, and target patterns with known distances and depths, allowing for precise positioning and calibration of the optical head along a reference line, ensuring accurate measurement and traceability to NIST standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If borescopes are calibrated by the manufacturer, then initial measurement accuracy is achieved, but measurement accuracy certification cannot be provided due to absence of adequate calibration standards
Solution Approach 1:
The calibration device is segmented into multiple reference surfaces at different known distances from the optical head, allowing separate calibration of depth and lateral measurements. This segmentation enables comprehensive accuracy certification without requiring a single complex calibration standard.
Solution Approach 2:
The calibration device transitions from conventional one-dimensional calibration to three-dimensional calibration by incorporating reference surfaces at multiple depths and lateral positions. This dimensional expansion enables full 3D measurement accuracy certification.
2Measurement precision
If conventional calibration methods are used, then simple one-dimensional calibration is achieved, but three-dimensional measurement accuracy cannot be verified
Solution Approach 1:
The calibration device serves multiple functions simultaneously: it provides depth calibration references, lateral distance calibration references, and optical axis alignment references. This multi-functionality enables comprehensive 3D calibration without requiring multiple separate calibration devices.
Solution Approach 2:
The fixture acts as an intermediary component that holds the optical head at a precise, fixed distance from the reference surfaces. This intermediary ensures accurate positioning and spacing relationships during calibration, enabling reliable 3D measurement verification.
3Ease of operation
If manufacturer calibration is performed, then initial setup is complete, but on-site verification and re-calibration capability is lost
Solution Approach 1:
The calibration device enables users to perform self-calibration and self-verification of borescope accuracy on-site. The device includes all necessary reference elements and fixtures needed for complete calibration, making external calibration services unnecessary and enabling immediate accuracy verification.
4Measurement precision
If multiple separate calibration devices are used for different measurement dimensions, then comprehensive calibration coverage is achieved, but device complexity and operational complexity increase
Solution Approach 1:
The patent merges depth calibration references, lateral calibration references, and alignment references into a single integrated calibration device. This consolidation provides comprehensive 3D calibration coverage while reducing the number of separate devices and simplifying the calibration process.
Data Source
AI summary
A borescope calibration device is provided that includes a base having a planar surface and a plurality of reference surfaces on a side of the base opposing the planar surface, each of the plurality of reference surfaces having a height that decreases along a length of the base, a fixture that positions an optical head along a reference line that is parallel to the planar surface and providing a fixed distance between the reference surfaces and the optical head, the fixture being movable along a length of the base, and a target pattern formed on each of the reference surfaces.