Boresight Mounting System Field Calibration via Sensor Repositioning
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Solution Overview
Problem
Current boresighting methods face accuracy issues due to mechanical misalignment, local gravity distortions, and internal device errors, which limit the precision of angular measurements and require factory calibration, making field replacements and recalibrations challenging.
Innovation Solution
A boresight mounting system with a tray and alignment measurement sensor that allows for angular orientation determination at multiple positions, calculating misalignment factors for pitch, roll, and yaw axes, and applying these corrections to improve accuracy, enabling field interchangeable and recalibration-capable systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current mounting methods are used, then device complexity is reduced, but measurement precision deteriorates due to mechanical misalignment and environmental factors
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with computational correction methods. Instead of using precision mechanical mounts to physically align sensors, the system uses removable mounting fixtures combined with mathematical algorithms that calculate and correct misalignment factors, substituting mechanical precision requirements with computational processing.
Solution Approach 2:
The system changes the approach from fixed mechanical parameters to variable computational parameters. By measuring misalignment factors and applying correction values dynamically, the system adapts to different mounting conditions and environmental factors, allowing the same hardware to achieve high precision through parameter adjustment rather than mechanical rigidity.
2Adaptability or versatility
If factory calibration is performed, then measurement precision is improved, but adaptability deteriorates because equipment cannot be replaced or recalibrated in the field
Solution Approach 1:
The system enables self-calibration in the field by providing tools and procedures that allow operators to perform calibration without returning to the factory. The removable mounting fixtures and correction algorithms empower users to maintain and recalibrate equipment on-site, making the system self-sufficient rather than dependent on external calibration services.
Solution Approach 2:
The calibration system is segmented into portable, removable components including detachable mounting fixtures and separate calibration tools. This segmentation allows the calibration capability to be independently transported and applied in the field, separating the calibration function from fixed factory infrastructure and enabling distributed calibration operations.
3Reliability
If rigid mounting is used, then measurement precision is improved, but reliability deteriorates due to wear and susceptibility to local environmental effects
Solution Approach 1:
The patent eliminates rigid mechanical mounting by substituting it with removable fixtures and computational correction. Instead of relying on permanently fixed, wear-prone mechanical connections, the system uses detachable mounts combined with algorithms that calculate misalignment and apply corrections, replacing mechanical permanence with computational stability.
Solution Approach 2:
The system transitions from static rigid mounting to dynamic adjustable mounting. The removable fixtures allow the system to adapt to different mounting surfaces and conditions, and the computational correction dynamically adjusts for misalignment, making the system flexible rather than fixed and resistant to wear rather than vulnerable to it.
Data Source
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Figure 3
AI summary
A calibration method comprises providing a mounting fixture including a tray coupled to a frame, and an alignment measurement sensor removably coupled to the tray. An angular orientation of the tray is determined using the alignment measurement sensor removably coupled to the tray in a first position. The alignment measurement sensor is then moved to a second position on the tray that is rotated from the first position, and the angular orientation of the tray is determined using the alignment measurement sensor at the second position. An axis misalignment for at least two of a pitch axis, a roll axis, or a yaw axis of the alignment measurement sensor is then calculated to determine one or more misalignment factors. The one or more misalignment factors are then applied to correct for misalignment of the alignment measurement sensor.