Curvilinear Reflective Surface for Parallel Laser Illumination
Solution Overview
Problem
Existing sensing devices for analyzing part profiles, such as wire ends, suffer from illumination field distortion and inefficiency due to non-parallel edges and the need for large device sizes, which limits their application in manufacturing environments.
Innovation Solution
A compact sensor device design utilizing a reflective surface with a curvilinear contour to shape and direct radiation into a parallel beam, allowing for a more compact and flexible illumination field that is not distorted, enabling effective use of the entire sensing element and accommodating various part positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a biconvex lens is introduced to create parallel illumination field edges, then illumination quality improves, but device size becomes too large
Solution Approach 1:
A reflective surface acts as an intermediary optical element to shape the illumination field from a laser diode into a parallel beam, eliminating the need for a biconvex lens while maintaining illumination quality
Solution Approach 2:
The patent replaces the mechanical lens-based optical system with a reflective surface-based system, achieving the same parallel beam effect with reduced spacing requirements and smaller device footprint
2Illumination intensity
If sufficient distance is maintained between laser diode and sensing element, then proper illumination is achieved, but device size increases
Solution Approach 1:
The reflective surface serves as a compact intermediary that redirects and shapes laser light into a parallel beam, enabling proper illumination at reduced distances between components
Solution Approach 2:
The reflective surface utilizes angular redirection of light paths to achieve parallel illumination without requiring increased linear spacing between the laser diode and sensing element
3Device complexity
If non-parallel illumination edges are used, then device complexity is reduced, but image distortion occurs
Solution Approach 1:
The reflective surface acts as a precision intermediary that shapes the illumination field to have parallel edges, eliminating image distortion while keeping the overall optical system simple
Solution Approach 2:
The reflective surface employs a curvilinear contour to redirect light rays and create parallel illumination edges, solving the distortion problem through geometric shaping
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 provides a compact and flexible sensor device that prevents distortion and allows for efficient use of the entire sensing element, improving manufacturing efficiency by reducing size constraints and part positioning requirements.
Implementation Method 1
a reflective surface having a contour for shaping and directing a radiation field such that it has at least two parallel sides
Data Source
AI summary
A sensor device includes a source of radiation and a reflective surface having a contour that directs radiation reflected from the surface along a field having at least two parallel sides. In a disclosed example, the reflective surface contour is at least partially curvilinear. A disclosed example includes a laser diode as the source of radiation and the reflective surface directs the reflected radiation in a direction that is generally perpendicular relative to a path that light follows as it emanates from the laser diode. The reflective surface in one example shapes the reflected radiation from a source that provides radiation along a path with obliquely oriented sides, the reflected radiation has at least two parallel sides. A disclosed sensor device is useful for measuring at least one feature of a part or object placed within a field of view of a sensing element that can detect the reflected radiation.