Flexible Lead Screw 2D Stage for Precision Assembly
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Solution Overview
Problem
Existing 2D stages are bulky, inefficient to assemble, and lack precision, making them unsuitable for high-precision and rapid measurement of large workpieces, which limits their use in image measurement and increases production costs.
Innovation Solution
An electric high-precision 2D stage design featuring a modular structure with X-axis and Y-axis cross guide rails, flexible lead screw mechanisms, and high-precision glass gratings, allowing for precise linear displacement in both directions with reduced assembly complexity and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing 2D stages use hard connected driving and connecting structures for X and Y axes, then the structure is stable, but the assembly process becomes complex and assembly efficiency decreases
Solution Approach 1:
The 2D stage is divided into three independent modules: bottom layer stage module, middle layer stage module, and upper layer stage module. Each module can be assembled and tested independently, then quickly connected through guide rails. This segmentation allows parallel assembly processes and reduces overall assembly time while maintaining structural integrity through standardized connection interfaces.
Solution Approach 2:
X-axis and Y-axis cross guide rails serve as intermediary components that connect different stage modules. These guide rails provide precise positioning and stable connection between modules without requiring complex hard-connected driving structures, thus simplifying assembly while maintaining reliability.
2Strength
If existing 2D stages use traditional hard connected structures, then the connection is rigid, but the precision decreases and the stage becomes easy to wear and offset after long-term use
Solution Approach 1:
The patent replaces rigid hard connections with flexible lead screw mechanisms that can dynamically adjust to positional variations and wear. The lead screw and nut block combination provides precise positioning capability while accommodating thermal expansion and minor misalignments, maintaining measurement precision over long-term use.
Solution Approach 2:
Traditional mechanical hard connections are replaced with a hybrid system combining lead screw mechanisms for driving and cross guide rails for positioning. This substitution reduces wear and offset by distributing mechanical stresses across multiple components with precise geometric constraints.
3Productivity
If the field of vision of the lens is increased to measure ultra-long workpieces in one time, then the measurement efficiency improves, but the manufacturing cost increases and precision decreases
Solution Approach 1:
Instead of using a single large-field lens, the system captures multiple images of the workpiece at different positions along the X and Y axes, then splices them together to form a complete view. This periodic imaging approach maintains high precision with standard lenses while achieving measurement of ultra-long workpieces through coordinated movement of the upper layer stage module.
4Strength
If existing 2D stages are designed with bulky structure, then the structural strength is sufficient, but the device becomes heavy and complex
Solution Approach 1:
The stage structure is segmented into three modular layers, each with standardized components and connection interfaces. This modularity reduces overall complexity by allowing independent design optimization of each module while maintaining sufficient structural strength through localized reinforcement at critical connection points.
Solution Approach 2:
Rather than designing a uniformly bulky structure, the patent applies structural reinforcement only where needed - at the guide rail connections and load-bearing points. The lead screw mechanisms and cross guide rails provide localized strength where required, while other areas use minimal necessary material, reducing overall weight and 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
The solution enhances assembly efficiency, maintains high precision over time, and supports large external loads, ensuring stable long-term precision and reducing production costs, enabling efficient measurement of large workpieces.
Implementation Method 1
the X-axis flexible lead screw mechanism includes an X-direction lead screw, an X-axis nut block, an X-direction push block
Implementation Method 2
the ball push rod and the ball head plunger are mounted on two sides of the X-direction slot, the X-direction push block is inserted in the X-direction slot, two sides of the X-direction push block are in point contact with the ball push rod and the ball head plunger, respectively
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present utility model provides an electric high-precision 2D stage, including: a bottom layer stage module, a middle layer stage module, and an upper layer stage module, where the bottom layer stage module is connected to the middle layer stage module through an X-axis cross guide rail, the middle layer stage module is connected to the upper layer stage module through a Y-axis cross guide rail, the bottom layer stage module is connected to the middle layer stage module through an X-axis feeding mechanism, the X-axis feeding mechanism includes an X-axis driving unit and an X-axis flexible lead screw mechanism, the X-axis driving unit is connected to the X-axis flexible lead screw mechanism, the X-axis flexible lead screw mechanism includes an X-direction lead screw, an X-axis nut block, an X-direction push block, an X-dome mounting connecting block, a ball push rod, and a ball head plunger. The present utility model has the advantages that the present utility model adopts a flexible connecting structure, thereby reducing the assembly requirement, and improving the assembly efficiency and the precision, and can still maintain a good precision stability after long-term use.