Circular Positioner Calibration Using Non-Contact Scanning
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Solution Overview
Problem
Conventional positioning and calibration methods for machines during installation are time-consuming and labor-intensive, lacking efficiency and accuracy.
Innovation Solution
A position calibration system comprising a positioning substrate, a positioner sensing module, and a control unit, which uses a robotic arm and non-contact distance sensors to automatically scan and record calibration reference points, enabling rapid and precise calibration of machine positions and compensating for position deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional positioning and calibration methods are used, then the machine components can be positioned according to standard sizes, but the calibration process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical measurement and adjustment methods with an automated optical sensing system. The positioner sensing module uses non-contact optical sensors to detect the circular positioner and automatically determine calibration reference points, eliminating the need for manual measurement tools and repeated mechanical adjustments.
Solution Approach 2:
The system enables self-calibration by automatically scanning the circular positioner, calculating intersected center positions, and storing calibration data without human intervention. The control unit autonomously processes sensor data to determine calibration reference points, making the calibration process self-executing and highly efficient.
2Measurement precision
If conventional calibration methods with repeated adjustments are used, then positioning accuracy can be improved, but the complexity of the calibration process increases
Solution Approach 1:
The patent incorporates a pre-designed circular positioner with distinct edge features on the positioning substrate before the calibration process begins. This preliminary preparation allows the sensing module to automatically detect and calculate calibration reference points through a single scan, eliminating the need for repeated adjustments and complex iterative procedures.
Solution Approach 2:
The system replaces complex manual calibration procedures with an automated optical detection and calculation system. The control unit automatically processes sensor data to determine intersected center positions and generates calibration data, significantly simplifying the overall calibration process while maintaining high accuracy.
3Ease of manufacture
If manual positioning methods are used, then the installation process can be completed, but labor costs and operational time increase
Solution Approach 1:
The patent replaces manual positioning operations with an automated robotic arm system equipped with non-contact distance sensors. The robotic arm executes scanning movements and the control unit automatically processes the data to generate calibration information, eliminating manual labor while dramatically improving calibration efficiency and productivity.
Solution Approach 2:
The system performs self-calibration by automatically scanning the circular positioner, calculating reference points, and storing calibration data without human intervention. This autonomous operation reduces labor requirements and operational time while maintaining high installation ease through automated processes.
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 allows for fast, accurate, and automatic calibration of machine positions and angles, simplifying the installation process, reducing labor and costs, and ensuring high positioning accuracy.
Implementation Method 1
a non-contact distance sensor unit, which can be mounted on the robotic arm. The control unit controls the robotic arm to move in the first direction and the second direction, and the non-contact distance sensor unit scans the upper surface of the positioning substrate
Data Source
AI summary
A position calibration system and method are disclosed, in which a control unit is provided to control a positioner sensing module to scan a circular positioner provided on a positioning substrate in a first direction and a second direction so as to acquire midpoints of two scanned line segments and acquire an intersection of lines extending from the two center points in a direction perpendicular to the first and the second directions as a calibration reference point, which correspond to a centroid (a center) of the circular positioner. The calibration reference point functions as a reference point for positioning the positioning substrate with respect to the positioner sensing module and is stored in a memory unit. The calibration reference point can be used as a positioning point during installation of a machine and can also be used for calibration of a position of the machine.