Confocal Sensor Optical Axis Alignment via Intensity Feedback
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Solution Overview
Problem
Existing confocal displacement sensors face challenges in accurately adjusting the posture of measurement head units, leading to reduced measurement accuracy due to difficulties in aligning optical axes, especially when one sensor head's optical axis is inclined relative to the other.
Innovation Solution
A confocal displacement sensor system that includes a light projecting unit, a head unit with a diffraction lens generating chromatic aberration, a spectroscope, and a control device displaying intensity information of determination light to aid in orthogonal alignment of optical axes, allowing for precise adjustment of the head unit's posture using a reference member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually adjusts the postures of two sensor heads to align optical axes, then the thickness measurement can be performed, but the alignment accuracy is insufficient and measurement precision deteriorates
Solution Approach 1:
The system displays intensity information of determination light in real-time during optical axis adjustment, providing visual feedback to guide the operator. The intensity value increases as the optical axis alignment improves, enabling precise adjustment without requiring expert skill while ensuring accurate thickness measurement.
Solution Approach 2:
The patent replaces manual mechanical adjustment of optical axes with an optical feedback system. Instead of relying solely on physical alignment skills, the system uses light intensity detection and display to guide the adjustment process, substituting mechanical expertise with an automated optical measurement and feedback mechanism.
2Device complexity
If the optical axis of one sensor head is inclined relative to the other, then the sensor heads can be positioned, but the optical axes cannot align and measurement accuracy is reduced
Solution Approach 1:
The system provides real-time intensity information feedback during optical axis adjustment. The intensity value serves as a quantitative indicator of alignment quality, allowing the operator to detect and correct inclination issues between sensor heads while maintaining simple positioning procedures.
Solution Approach 2:
The system uses intensity information display to indicate alignment status. The changing intensity value acts as a visual signal that guides the operator in correcting optical axis inclination, transforming the invisible alignment quality into a visible and adjustable parameter.
3Productivity
If traditional optical axis adjustment methods are used, then the adjustment process can be completed, but it requires high skill level and time is consumed
Solution Approach 1:
The real-time display of determination light intensity provides continuous feedback during the adjustment process. This allows the operator to make informed adjustments without requiring extensive experience, reducing both the time needed and the skill level required while maintaining adjustment effectiveness.
Solution Approach 2:
The system enables the adjustment process to guide itself through automated feedback. The intensity information automatically indicates the alignment status, allowing the system to partially perform the adjustment guidance function without external expertise, thereby improving efficiency and reducing procedural complexity.
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
Enables easy and accurate adjustment of the head unit's posture, ensuring high-accuracy measurements by visually displaying intensity information, thereby aligning optical axes and improving measurement precision.
Implementation Method 1
a first confocal optical system having a first diffraction lens, generating chromatic aberration along an optical axis direction in the light emitted by the light projecting unit
Implementation Method 2
a first spectroscope which divides a first light by each wavelength, the first light having been reflected by the first surface and having passed through the first confocal optical system
Implementation Method 3
a first light receiving unit which receives the divided first light for each wavelength and acquires an intensity of the light for each wavelength
Data Source
AI summary
Optical axes of lens units of measurement heads are adjusted so as to be parallel to each other. The lens unit includes a diffraction lens. When adjusting the optical axis, in a state where the measurement heads face each other with a reference member interposed therebetween, light having a plurality of wavelengths are emitted from the measurement heads to one surface and the other surface of the reference member, respectively. Intensities of primary light having one wavelength, which are reflected by one surface and the other surface of the reference member respectively, and incident on the measurement heads through each of a path of a multi-order light having other wavelengths are displayed on a main display unit as information indicating a degree of orthogonality of the optical axes of the measurement heads with respect to the one surface and the other surface of the reference member.