Component Aligner for Laser and IR Sensor Precision
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Solution Overview
Problem
Current laser-based thermal temperature sensors require labor-intensive and costly manual alignment of a laser pointer with an infrared spot sensor, which is prone to misalignment due to mechanical shocks or movements, especially when the system is moved or dropped, leading to inaccuracies in temperature measurements.
Innovation Solution
A component aligner is used to securely position a laser pointer and an infrared array sensor with a known angular relationship, allowing for software-based alignment during factory calibration, eliminating the need for manual aiming and maintaining alignment even when the system is moved or subjected to mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of laser pointer with infrared spot sensor is performed, then alignment can be achieved, but the process is labor intensive and costly
Solution Approach 1:
The patent applies preliminary action by pre-aligning the laser pointer and infrared spot sensor at the factory using a alignment tool with bores and slots that establish precise angular relationships. This pre-alignment is performed before the device reaches the user, eliminating the need for labor-intensive manual alignment in the field and reducing both time and cost.
Solution Approach 2:
The patent uses an alignment tool as an intermediary device that facilitates precise alignment between the laser pointer and infrared spot sensor. This tool includes bores and slots that act as mediators to establish the correct angular relationship, replacing direct manual alignment and reducing the skill time required.
2Measurement precision
If manual alignment is performed, then initial alignment can be achieved, but misalignment occurs when system is moved or dropped
Solution Approach 1:
The patent merges the laser pointer and infrared spot sensor into a single integrated housing with a common reference frame. By combining these components and establishing fixed angular relationships through the housing structure, the system maintains alignment stability even when moved or dropped, eliminating the misalignment problems of separate manually-aligned components.
Solution Approach 2:
The factory pre-alignment process establishes a stable baseline alignment that is locked in during manufacturing. This preliminary action creates a reliable starting point that maintains accuracy under normal operational conditions including movement and dropping, without requiring field adjustment.
3Measurement precision
If separate elongated aiming device with epoxy is used, then laser pointer can be positioned, but alignment is only precise at a given distance due to parallax
Solution Approach 1:
The patent combines the laser pointer and infrared spot sensor in a fixed angular relationship within a common housing, eliminating the separate aiming device approach. This integration removes parallax errors entirely because both components share a common reference frame, allowing accurate temperature measurements at any distance without the limitations of distance-specific alignment.
Data Source
AI summary
An apparatus comprising a component aligner including a base having a first side and a second side opposite the first side, and a first wall with first and second ends. The first wall extends from the second side of the base. The first end of the first wall is adjacent the second side of the base and opposite the second end of the first wall. The first wall includes a first interior wall surface defining a first bore configured for fixed placement of a first component. The apparatus includes a second wall including first and second ends, extending from the second side of the base. The first end of the second wall is adjacent the second side of the base and opposite the second end of the second wall. The second wall includes a second interior wall surface defining a second bore configured for fixed placement of a second component.