Color Wheel Dot Mask Balancing
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Solution Overview
Problem
Current balancing methods for color wheels in projectors are complex, time-consuming, and costly, especially for high-speed applications, as they require precise and iterative processes to achieve dual plane balancing, which is necessary for maintaining high picture quality and operational life under high rotational speeds.
Innovation Solution
A color wheel with a dot mask structure on its surface, featuring a plurality of wells for receiving balancing mass, allowing for efficient static positive balancing by filling wells of varying sizes to correct unbalance, enabling both rough and fine balancing without the need for iterative corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If classical static balancing methods (drilling holes or adhering weights) are used, then balancing can be achieved, but the process becomes time-consuming and expensive due to iterative corrections and bearing damage risks
Solution Approach 1:
The balancing mass is segmented into discrete portions that can be independently placed in different wells. The dot mask contains multiple wells of varying sizes and positions, allowing the balancing mass to be divided into separate units that can be strategically positioned to achieve precise balancing in a single step without iterative corrections
Solution Approach 2:
The dot mask with pre-defined wells is created before the balancing process. The wells are strategically positioned and sized in advance to provide ready-made locations for placing balancing mass, eliminating the need for iterative trial-and-error corrections and reducing balancing time significantly
2Manufacturing precision
If positive balancing by adhering weights is used, then unbalance can be corrected, but the adhesive may smear out and hardening takes time, increasing cost and complexity
Solution Approach 1:
Different regions of the dot mask have different properties - wells of varying sizes and positions are created to match specific balancing requirements. Each well is locally optimized for its intended purpose, allowing precise mass distribution without complex adhesive procedures or iterative adjustments
Solution Approach 2:
The invention uses simple, easily attachable balancing mass units that can be placed in the pre-defined wells. These are inexpensive components that eliminate the need for expensive adhesives, complex positioning procedures, and time-consuming hardening processes
3Manufacturing precision
If dual plane balancing is performed iteratively, then high picture quality is achieved, but the process becomes expensive and time-consuming
Solution Approach 1:
The dot mask is designed with wells distributed across different planes and positions, allowing balancing mass to be segmented and placed in specific wells to simultaneously address unbalance in multiple planes. This enables dual plane balancing to be achieved in a single operation rather than through costly iterative procedures
Solution Approach 2:
The dot mask serves multiple functions - it provides wells for single-plane balancing, wells for dual-plane balancing, and allows for both rough and fine balancing in one integrated structure. This multi-functionality eliminates the need for separate balancing procedures and reduces manufacturing costs
Data Source
AI summary
The present invention relates to a color wheel which allows for an easy to perform balancing. The color wheel comprises a motor and a color rotor with a carrier. Filter segments are mounted to the carrier. In addition the color rotor comprises a body with a surface perpendicular to the rotational axis of the rotor. The surface comprises a two dimensional matrix of holes which can be filled with balancing masses. In order to balance the color rotor it is rotated. During rotation, the unbalance is detected. In addition the location where to put balancing mass is detected. At this location balancing mass, such as for example adhesive is filled into the respective hole.