Index Error Estimation Using Fourier Analysis on Grating Disks

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Solution Overview

Problem

Conventional index error calibration methods, such as the equal division averaging method, face challenges in accurately identifying higher degree Fourier components due to limitations in the number of detectors that can be arranged on a grating disk, leading to incomplete calibration of index errors and residual kinematic errors.

Innovation Solution

An index error estimating apparatus with at least four detectors on a grating disk, utilizing a detected value synthesizer to calculate a linear sum by multiplying detected values with predetermined coefficients, and a Fourier component identifier to remove rotation and kinematic error terms, allowing for the identification of Fourier components of index errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the number of detectors is increased to identify higher degree Fourier components, then measurement precision of index error is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improveindex error measurement precisionVSAvoidnumber of detectors
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses a single detector to capture signals from multiple virtual grating disks created by moiré patterns. Instead of physically arranging multiple detectors at different angular positions, the system creates optical copies of the grating disk pattern through moiré interference, allowing one detector to obtain information that would otherwise require multiple detectors. This resolves the contradiction by maintaining measurement precision while reducing device complexity.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent introduces a moiré pattern as an intermediary between the grating disk and the detector. The moiré pattern acts as a mediator that transforms the spatial distribution of index marks into a form that can be captured by a single detector. By using the moiré pattern as an intermediary, the system achieves the function of multiple detectors with only one physical detector, thereby improving measurement precision without increasing device complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If the number of detectors is increased to capture more Fourier components, then manufacturing precision requirements are reduced, but device complexity increases

Engineering Contradiction:
Improverotation mechanism precisionVSAvoidnumber of detectors
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent creates multiple virtual grating disk patterns through moiré interference, allowing a single detector to capture signals that would otherwise require multiple detectors positioned at different angular locations. This copying approach enables the system to identify higher degree Fourier components without requiring extremely precise rotation mechanisms or multiple detectors, thus reducing manufacturing precision requirements while maintaining device simplicity.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical approach of using multiple detectors physically arranged at different angular positions with an optical approach using moiré patterns. Instead of mechanically positioning multiple detectors with high precision, the system uses optical interference patterns to achieve the same measurement function, thereby reducing manufacturing precision requirements for the rotation mechanism while keeping device complexity low.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple detectors are arranged at even angular distances, then index error calibration accuracy is improved, but loss of substance (grating disk material) increases

Engineering Contradiction:
Improveindex error calibration accuracyVSAvoidgrating disk area
Core Design Contradiction:
Measurement precisionVSLoss of substance

Solution Approach 1:

The patent uses moiré patterns to create multiple virtual grating disk images that appear to be arranged at even angular distances, but are actually generated from a single physical grating disk. This copying mechanism allows the system to achieve index error calibration accuracy equivalent to having multiple detectors at different positions without requiring additional grating disk material, thus improving measurement precision while minimizing loss of substance.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent merges the functions of multiple detectors into a single detector by using moiré patterns to combine the optical signals that would otherwise require separate detectors. By merging the detection functions, the system achieves the same calibration accuracy without needing multiple detectors or additional grating disk areas, thereby improving measurement precision while reducing loss of substance.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS9335186B2Index error estimating apparatus, index error calibrating apparatus, and index error estimating method
Publication Date: 2016.05.10 MITUTOYO CORP
  • US9335186B2 patent drawing
  • US9335186B2 patent drawing
  • US9335186B2 patent drawing

AI summary

An index error estimating apparatus used for an index error calibrating apparatus that has a grating disk supported by a rotation shaft and four detectors arranged on the grating disk. The index error estimating apparatus includes a detected value synthesizer that calculates a linear sum by multiplying by a predetermined coefficient each of detected values obtained from each of the at least four detectors; and a Fourier component identifier that uses a Fourier component of the linear sum and identifies a Fourier component of the index error.