Dual-LED Cutting Tool Illumination for Precise Shadow Alignment
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Solution Overview
Problem
Known cutting machines with a single LED illuminator struggle to clearly cast a shadow of the cutting tool on the workpiece, especially when the machine body is at the top dead center, leading to misalignment with ink lines drawn on the workpiece.
Innovation Solution
A cutting machine design featuring a dual-LED illuminator with strategically positioned first and second light sources and lenses, where the distance between the light source centers is shorter than the sum of their respective distances from the emission surfaces, ensuring clear shadow casting on the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single LED illuminator is used, then the device complexity is reduced, but the shadow casting clarity and alignment precision deteriorate
Solution Approach 1:
The single LED illuminator is segmented into two separate LED light sources (first LED and second LED) positioned at different locations. Each LED casts light through its own lens onto the workpiece, creating two complementary shadows that together provide clear, precise alignment markings for the cutting tool path.
Solution Approach 2:
The illumination system transitions from a single-point light source to a distributed multi-point light source arrangement. The first and second LEDs are positioned at different spatial coordinates, creating illumination from multiple dimensions that collectively improve shadow clarity and alignment precision across the workpiece surface.
2Area of stationary object
If the distance between light source centers is increased, then the coverage area is expanded, but the shadow clarity and brightness uniformity deteriorate
Solution Approach 1:
The patent optimizes the distance parameter between the first and second LED light source centers relative to their respective lens emission distances. By controlling this geometric parameter to be shorter than the sum of the emission distances, the system achieves both adequate coverage area and uniform shadow brightness without excessive separation that would cause illumination inconsistency.
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
This design effectively aligns and clearly casts the shadow of the cutting tool on the workpiece, improving precision and accuracy during cutting operations by reducing light brightness unevenness and optical loss.
Implementation Method 1
a first lens having a first incidence surface to receive light incident from the first light source and a first emission surface through which light is emittable
Implementation Method 2
The shadow of the cutting tool is cast on the surface of the workpiece placed below the cutting tool
Data Source
AI summary
An illuminator that emits light from a radially outer portion of the cutting tool toward the cutting tool includes a first light source and a second light source, and a first lens and a second lens. The first lens has a first emission surface including a first outermost portion located farthest and at a first distance from a first center axis including a first light source center of the first light source and perpendicular to the first light source. The second lens has a second emission surface including a second outermost portion located farthest and at a second distance from a second center axis including a second light source center of the second light source and perpendicular to the second light source. A distance between the first center axis and the second center axis is shorter than a sum of the first distance and the second distance.