Infra-Red Sensor Alignment for Moving Hot Extruded Bodies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for aligning infra-red sensors with hot extruded bodies in metal extrusion processes are time-consuming, prone to errors, and inefficient, especially when dealing with lateral movement and die changes, which affects production efficiency and product quality.
Innovation Solution
An automated system that uses an infra-red sensor with a scanner and processor to analyze infra-red radiation profiles, automatically align and re-align the sensor with the extruded body, adjusting for lateral movement and die changes, ensuring accurate temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of infra-red sensor is used with laser guide spot, then alignment can be achieved, but the process is time-consuming and dangerous
Solution Approach 1:
The patent replaces the manual mechanical alignment system with an automated optical system. The infra-red sensor automatically detects the extruded body's position and orientation using optical fields, eliminating the need for manual mechanical positioning with laser guides. This substitution achieves both high alignment precision and rapid positioning without operator intervention.
2Measurement precision
If manual alignment is used, then initial positioning can be achieved, but lateral movement of extrusion causes misalignment
Solution Approach 1:
The patent implements a feedback mechanism where the infra-red sensor continuously monitors the extruded body's position and orientation. The sensor data is processed to detect lateral movements, and the system automatically adjusts the sensor's positioning in real-time to maintain accurate alignment. This closed-loop feedback ensures both initial precision and ongoing stability despite extrusion movement.
3Ease of operation
If infra-red sensor position is controlled manually, then alignment can be adjusted, but correction for lateral movement is difficult
Solution Approach 1:
The patent enables the infra-red sensor system to perform self-alignment and self-correction automatically. The sensor detects lateral movements of the extruded body and autonomously adjusts its own positioning without requiring manual intervention. This self-service capability dramatically improves the speed of alignment correction while maintaining ease of operation through automated control.
4Measurement precision
If spot thermometer is mounted above extrusion press, then temperature monitoring is possible, but alignment with extruded body is problematic
Solution Approach 1:
The patent transforms the static mounting position of the infra-red sensor into a dynamic system. The sensor is mounted above the extrusion press in a fixed position but incorporates dynamic adjustment capabilities through automated positioning mechanisms. This allows the sensor to maintain optimal alignment with the extruded body dynamically, combining the advantages of fixed mounting with the flexibility of adjustable positioning.
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 rapid, accurate, and efficient alignment of infra-red sensors, improving temperature monitoring and control in metal extrusion processes, reducing downtime and ensuring consistent product quality across multiple cavities and stages of processing.
Implementation Method 1
an infra-red sensor having an axis along which radiation is received
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An apparatus is disclosed for automatically aligning an infra-red sensor (2) with a hot extruded body. The apparatus includes a scanner (16) such as a motor that can point the infra-red sensor that the axis of the infra-red sensor is pointed in a plurality of directions. A central control unit (14), which is a processor, is configured to analyse the amount of infra-red radiation received in the plurality of positions, to identify a first position in which the axis of the infra-red sensor points at a first extruded body by measuring the amount of radiation received in the first position and in a plurality of positions around the first position, and to instruct the scanner to move the infra-red sensor to the first position so that the temperature of the first extruded body can be measured.