Encoder Alignment via Resilient Support and Adjustment
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Solution Overview
Problem
Conventional methods lack a structured approach for properly aligning encoders with linear scales, leading to erroneous measurements and reduced productivity in automation systems, semiconductor manufacturing, and display manufacturing.
Innovation Solution
An encoder aligning apparatus comprising a first support member connected to a moveable unit, a second support member connected through resilient members, and adjustment members that adjust the distance and angle between the support members to align the encoder with the linear scale, utilizing contact grooves and resilient members for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If no alignment structure is provided for the encoder and linear scale, then the device structure remains simple, but the measurement precision deteriorates due to misalignment
Solution Approach 1:
The patent introduces a second support member as an intermediary component between the first support member (attached to movable unit) and the encoder. This second support member provides a dedicated mounting interface for the encoder, enabling precise alignment with the linear scale without complicating the overall structure. The intermediary component isolates the alignment function from the main structural elements.
Solution Approach 2:
The support structure is segmented into multiple independent components: a first support member connected to the movable unit, a second support member for mounting the encoder, and adjustment members. This segmentation allows each component to perform its specific function independently, with the second support member specifically dedicated to encoder alignment, thereby improving measurement precision without requiring complete structural redesign.
2Productivity
If the encoder is misaligned with the linear scale, then the device structure remains simple, but the productivity deteriorates due to erroneous measurements
Solution Approach 1:
The patent incorporates adjustment members that enable dynamic alignment of the encoder with the linear scale. The adjustment members allow the encoder's position and orientation to be modified during installation or maintenance, ensuring proper alignment for accurate measurements. This dynamic adjustment capability prevents productivity loss from misalignment without requiring overly complex fixed alignment structures.
Solution Approach 2:
The adjustment members enable changes in positional parameters (distance and angle) between the encoder and the linear scale. By providing mechanisms to adjust these parameters, the system ensures optimal alignment for accurate measurements, thereby maintaining high productivity in manufacturing applications without sacrificing device simplicity.
3Ease of repair
If misalignment is detected during operation, then measurement accuracy can be monitored, but the ease of repair deteriorates due to difficulty in correcting alignment
Solution Approach 1:
The second support member serves as an intermediary that provides accessible adjustment interfaces for the encoder. This intermediate component allows alignment corrections to be made without disassembling the entire encoder system or moving the movable unit, significantly improving ease of repair and maintenance while keeping the adjustment mechanism relatively simple.
Solution Approach 2:
The adjustment members are pre-configured to enable alignment corrections during installation or maintenance phases. By providing built-in adjustment capabilities in the support structure, the system allows alignment issues to be corrected before they affect production, or easily fixed during maintenance without requiring complex diagnostic and correction procedures.
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 accurate alignment of the encoder with the linear scale, improving measurement accuracy and enhancing manufacturing productivity and efficiency in equipment employing encoders.
Implementation Method 1
a second support member connected to the first support member through a resilient member
Data Source
AI summary
An encoder aligning apparatus includes: a first support member connected to a moveable unit moved along a base; a second support member connected to the first support member through a resilient member, the second support member being provided with an encoder facing a linear scale attached to said base; and an adjustment member penetrating the first support member to contact the second support member for adjusting the distance and the angle between the first support member and the second support member so as to properly align the encoder with the linear scale.