Grade Arm Feedback Sensor for Laser Tilt Accuracy
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Solution Overview
Problem
Conventional rotating construction lasers face accuracy issues due to accumulated errors and wear in the lead screw mechanism, leading to deviations in angle settings, and lack a reliable feedback-control system to confirm set grades or show errors, resulting in incorrect inclinations and the need for recalibration.
Innovation Solution
A high-accuracy home and narrow-range grade sensor system with a feedback sensor that detects the position of the grade arm and calculates tilting angles, using a simple optical linear sensor and a pin mounted directly on the grade arm, eliminating complex setups and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lead screw mechanism with stepper motor is used to tilt the grade arm, then the grade mechanism can be controlled and positioned, but accumulated errors and wear occur due to repetitive use, leading to deviations in angle setting
Solution Approach 1:
The patent implements a feedback sensor system that includes an optical linear sensor and a pin mounted on the grade arm. The pin casts a shadow on the optical linear sensor, creating a feedback signal that indicates the actual position of the grade arm. This feedback mechanism allows the system to detect deviations from the desired position and correct them, thereby maintaining angle setting accuracy despite wear and accumulated errors in the lead screw mechanism.
Solution Approach 2:
The patent replaces complex mechanical positioning verification methods with an optical feedback system. Instead of relying solely on mechanical encoders or physical measurements, the system uses an optical linear sensor to detect the position of the pin mounted on the grade arm. This substitution of mechanical detection with optical detection improves reliability by reducing wear and increasing measurement precision.
2Measurement precision
If a feedback sensor system with pattern plate and CCD array scanner is used, then position detection is possible, but the setup becomes complex and production cost increases
Solution Approach 1:
The patent extracts only the essential elements needed for position detection, eliminating unnecessary components. Instead of using a complex pattern plate with multiple features, the invention uses a simple pin that casts a shadow. Instead of a CCD array scanner, it uses an optical linear sensor. This extraction of essential functionality reduces device complexity while maintaining measurement precision.
Solution Approach 2:
The patent employs inexpensive optical components - a simple pin, an LED light source, and an optical linear sensor - replacing expensive components like pattern plates and CCD array scanners. These simpler components achieve the same position detection function at lower cost and with reduced complexity, making the system more economical for production while maintaining adequate measurement precision.
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 ensures precise and reliable return to the home position, correcting for deviations in the nut and grade arm connection, achieving high accuracy within +/-4% of the grade setting, and is cost-effective with minimal components, enhancing instrument accuracy and reducing recalibration needs.
Implementation Method 1
a feedback sensor system, which is configured to detect a position of the grade arm and/or to calculate a tilting angle based on the position of the grade arm
Data Source
AI summary
Rotating construction laser device with a grade mechanism, including a code element and a position detection device for providing and detecting a feedback position information, and a leveling mechanism, which supports a lens barrel tiltably and is designed to tilt the lens barrel in order to have the level position detected by a tilt sensor and therewith to level the grade arm, the code element or the position detection device is arranged directly on the grade arm, and the feedback position information directly depends on the position of a reference point on the grade arm, the reference point being defined by the code element or the position detection device, respectively, thus allowing to deduce a position of the grade arm directly from the feedback position information, and/or to calculate a tilting angle of the grade arm with respect to the lens barrel directly from the feedback position information.