Calibration Standard Mounting for Thermal Expansion Compensation

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Solution Overview

Problem

Existing methods for calibrating laser projectors fail to account for temperature-induced changes in the calibration pattern's size and location within the manufacturing environment, leading to potential distortion and interference with manufacturing operations.

Innovation Solution

A mounting apparatus with a fixture comprising first, second, and third mounts that allow a calibration standard to move unrestrained along three mutually-orthogonal directions, preventing distortion due to thermal expansion or contraction, and enabling repeatable positioning at various locations within the work zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the calibration standard is rigidly fixed to prevent movement, then positioning stability is improved, but thermal expansion and contraction cause distortion of the measurement pattern

Engineering Contradiction:

Improvepositioning stabilityVSAvoidmeasurement pattern distortion

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The mounting apparatus transitions from a rigid fixed mounting to a dynamic adjustable mounting system. The calibration standard is mounted on adjustable mounts that allow movement in response to thermal expansion and contraction, enabling the system to adapt to temperature changes while maintaining measurement accuracy.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the mounting parameters from fixed to adjustable, allowing the calibration standard to move along the optical axis and laterally. This parameter adjustment compensates for thermal effects and maintains the integrity of the measurement pattern under varying temperature conditions.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the calibration standard is allowed to move freely, then thermal expansion and contraction are accommodated, but positioning stability and repeatability deteriorate

Engineering Contradiction:

Improvemeasurement pattern distortionVSAvoidpositioning stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The system incorporates feedback through adjustable mounts that can be repositioned and locked. After thermal expansion or contraction occurs, the operator can adjust the mounts to restore the calibration standard to its correct position, providing feedback-based correction to maintain positioning stability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The mounting system is designed to be dynamically adjustable rather than statically fixed. The mounts can be moved to accommodate thermal changes and then secured to provide stable, repeatable positioning, combining the benefits of both mobility and stability.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If the calibration pattern is left in the work zone after calibration, then calibration accuracy is maintained, but interference with manufacturing operations occurs

Engineering Contradiction:

Improvecalibration accuracyVSAvoidinterference with manufacturing operations

Core Design Contradiction:

Measurement precisionVSObject-generated harmful factors

Solution Approach 1:

The calibration standard is extracted from the permanent work zone environment and mounted on a portable apparatus. After calibration is completed, the calibration standard can be removed from the work zone entirely, eliminating interference with manufacturing operations while maintaining calibration accuracy during the calibration process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mounting apparatus provides dynamic positioning capabilities, allowing the calibration standard to be placed at various locations within the work zone during calibration, then easily removed or repositioned afterward. This dynamic flexibility resolves the conflict between maintaining calibration presence and avoiding manufacturing interference.

Inventive Principle:

Principle #15Dynamics

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 solution ensures accurate calibration of laser projectors by minimizing distortion of measurement patterns, allowing for precise positional accuracy and ease of calibration at multiple positions within the work zone without interfering with manufacturing operations.

Implementation Method 1

distortion of a known measurement pattern (e.g., a calibration pattern) of the calibration standard may be prevented

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

distortion of a known measurement pattern (e.g., a calibration pattern) of the calibration standard may be prevented

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS9347766B2Method of supporting an item in a mounting apparatus

Publication Date: 2016.05.24 THE BOEING CO

AI summary

A method of supporting an item in a mounting apparatus includes providing an item having first, second, and third members that are at least partially-spherical. The method additionally includes supporting the first member with a first mount configured to constrain the first member against movement along three mutually-orthogonal directions. The method also includes supporting the second member with a second mount configured to constrain the second member against movement along exactly two of the directions, and supporting the third member with a third mount configured to constrain the third member against movement along exactly one of the directions.