Gear Inspection Laser Alignment Using Six-Axis Reflection Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gear inspection systems face challenges in accurately aligning lasers for optimal inspection, leading to suboptimal gear quality and potential damage due to variations caused by grinding wheel breakdowns.
Innovation Solution
A gear inspection system employing a six-point adjustment system, including horizontal, vertical, depth, roll, pitch, and yaw adjustments, to precisely align a laser with a gear, using a processor to transform user inputs into adjustment instructions for the laser's orientation, allowing for independent adjustments in each orientation and automatic alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser is used for gear inspection, then inspection capability is provided, but alignment precision is insufficient leading to suboptimal gear quality
Solution Approach 1:
The system performs preliminary alignment actions by emitting test signals and receiving reflections before the actual inspection. The processor calculates orientation adjustments based on signal reflections from the gear surface, preparing the laser in the optimal position and orientation before conducting the full inspection, thereby ensuring both alignment precision and gear quality
Solution Approach 2:
The system uses feedback from the reflected signals to continuously adjust and verify laser alignment. The processor analyzes the reflected signals and automatically adjusts the laser orientation to maximize signal quality, creating a closed-loop control system that ensures precise alignment and accurate gear inspection results
2Area of stationary object
If multiple lasers are used to ensure coverage, then inspection coverage is improved, but device complexity increases
Solution Approach 1:
The system replaces multiple static lasers with a single dynamic laser that can change its orientation and position. The six-point adjustment system enables the laser to dynamically adapt its beam direction and focal point to cover different areas of the gear, achieving comprehensive inspection coverage with reduced device complexity
Solution Approach 2:
The single laser is designed to perform multiple functions by adjusting its orientation through the six-point system. It can inspect different gear features, adjust to various gear sizes and positions, and adapt to different inspection requirements, replacing what would traditionally require multiple dedicated lasers
3Adaptability or versatility
If manual adjustment of laser orientation is used, then alignment flexibility is provided, but time consumption increases
Solution Approach 1:
The system replaces manual mechanical adjustment with an automated control system. The processor receives signals from the user interface, calculates the required orientation adjustments, and automatically controls the six-point adjustment system to position the laser, eliminating time-consuming manual operations while maintaining full alignment flexibility
Solution Approach 2:
The system performs self-alignment by automatically calculating and executing the necessary orientation adjustments based on received signals and gear characteristics. The processor and adjustment system work together to autonomously optimize laser positioning without requiring continuous manual intervention, reducing alignment time while preserving adaptability
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 solution enables precise alignment of the laser with the gear, reducing the need for multiple lasers and minimizing manual adjustments, resulting in improved gear inspection accuracy and reduced scrapping of suboptimal gears, while allowing for efficient storage of optimal orientations for future inspections.
Implementation Method 1
emitting a first signal from a laser to a point of interest of the gear. A reflection of the first signal is received as the first signal reflects off the point of interest of the gear
Data Source
AI summary
A process for aligning a laser in a gear inspection system is disclosed. The method comprises fixing a gear for inspection within a gear inspection system and emitting a first signal from a laser to a point of interest of the gear. A reflection of the first signal is received as the first signal reflects off the point of interest of the gear. Based on the reflection of the first signal, an orientation of the laser is adjusted. Subsequently, a second signal is emitted from the laser to the point of interest of the gear, and a reflection of the second signal is received as the second signal reflects off the point of interest of the gear. Values corresponding to the orientation of the laser are stored based on the reflection of the second signal.