Electro-Optical Sensor Holder for Adjustment-Free Alignment
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Solution Overview
Problem
Existing electro-optical sensors face significant manufacturing-related positional tolerances, requiring complex and labor-intensive manual adjustments to achieve precise alignment with camera lenses, especially for high-quality applications like digital large-format photography and imaging metrology, which conventional methods struggle to meet the required micrometer-level accuracy.
Innovation Solution
A method involving a position-defined arrangement of electro-optical sensors in a non-adjustable receiving structure, utilizing a measuring unit to determine position transformations and compensating for shape deviations through a custom-designed sensor holder, allowing precise alignment without manual adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment is used to achieve precise sensor alignment, then positioning accuracy is improved, but production complexity and time consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-determining the position transformation of the sensor before final assembly. A measuring unit captures the actual position of the light-sensitive plane relative to the sensor housing, and this information is used to pre-calculate compensation values that are stored in memory. During assembly, these pre-calculated values guide the positioning, eliminating the need for complex manual adjustments and achieving high precision directly from the first assembly attempt.
2Manufacturing precision
If manual adjustment is performed to achieve precise alignment, then positioning accuracy is improved, but production time increases
Solution Approach 1:
The system performs preliminary measurement and calculation of position transformations before assembly. The measuring unit determines the actual position of the light-sensitive plane, calculates the required compensation, and stores this information in advance. This allows the assembly process to proceed quickly using pre-determined positioning data, eliminating time-consuming manual adjustments while maintaining high precision.
Solution Approach 2:
The patent implements self-service by enabling the sensor system to automatically determine and compensate for its own positioning deviations. The measuring unit and control unit work together to automatically calculate position transformations and guide the assembly process without requiring manual intervention or complex adjustment mechanisms, thereby speeding up production while maintaining accuracy.
3Ease of manufacture
If conventional sensor mounting is used, then ease of manufacture is improved, but positioning accuracy deteriorates
Solution Approach 1:
The patent introduces an intermediary measurement and control system between the sensor housing and the final assembly. The measuring unit determines the actual position of the light-sensitive plane, and the control unit calculates position transformations based on this data. This intermediary system provides precise positioning information that guides the assembly process, achieving high accuracy without complicating the manufacturing process, as the measurement and calculation are performed automatically.
Solution Approach 2:
The patent replaces complex mechanical adjustment systems with an automated measurement and control system. Instead of using manual adjusting screws or mechanical alignment mechanisms, the system uses a measuring unit to determine position, a control unit to calculate transformations, and a display unit to guide assembly. This substitution eliminates the need for skilled manual adjustment while achieving superior positioning accuracy.
4Manufacturing precision
If multiple sensors are aligned manually, then positioning accuracy is improved, but operational complexity increases
Solution Approach 1:
The system enables self-service by allowing multiple sensors to automatically determine and compensate for their own positioning deviations. Each sensor's measuring unit captures its position relative to the sensor housing, and the control unit calculates individual position transformations for each sensor. This automated process eliminates the need for operators to manually align multiple sensors, significantly reducing operational complexity while maintaining high precision across all sensors.
Data Source
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AI summary
The invention relates to a sensor arrangement (1) comprising at least one electro-optical sensor (2) which is secured to a receiving structure (8) of a sensor holder (9). The electro-optical sensor (2) comprises a sensor housing (3) with an optically active sensor layer (4) that is arranged thereon. The optically active sensor layer (4) forms a light-sensitive plane (5). The sensor holder (9) comprises a non-adjustable receiving structure (8) which compensates for a change in a previously determined shape of the electro-optical sensor (2) from a desired shape.