Integrated Laser Scanner Deflector and Angle Scale
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Solution Overview
Problem
Conventional laser scanners face challenges in reliable and cost-effective angle monitoring due to loose connections between the motor and the rotating mirror, leading to measurement inaccuracies and increased manufacturing costs, particularly in safety applications where precise angular position detection is critical.
Innovation Solution
A one-piece design where the angle measuring unit is integrally coupled with the deflection unit, eliminating separate manufacturing and assembly steps, and using a code disk or toothed wheel with a central opening for the motor shaft, allowing for reliable and precise angle measurement without the need for additional attachment surfaces or monitoring for slip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate line disc and rotating mirror are used in conventional laser scanners, then angle measurement can be performed, but the connection between components becomes loose leading to measurement inaccuracies and increased manufacturing complexity
Solution Approach 1:
The patent combines the line disc and rotating mirror into a single integrated component where the line disc is formed directly on the rotating mirror as one piece. This eliminates the separate connection interface between the line disc and mirror, preventing loosening and slip while maintaining accurate angle measurement functionality.
2Measurement precision
If separate line disc and rotating mirror components are used, then angle measurement is possible, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The line disc and rotating mirror are merged into a single component that is manufactured as one piece, eliminating separate assembly steps and reducing the number of parts. This integration simplifies the overall device structure and reduces assembly complexity while preserving the angle measurement capability.
Solution Approach 2:
The rotating mirror serves dual functions: it acts as both the deflecting element for the laser beam and as the carrier of the line disc for angle measurement. This multi-functionality reduces the total number of components needed in the system.
3Measurement precision
If separate line disc and rotating mirror are used, then angle measurement can be performed, but manufacturing costs increase due to additional components and processes
Solution Approach 1:
By forming the line disc directly on the rotating mirror as an integrated component, the patent eliminates the need for separate manufacturing and assembly processes for two distinct parts. This reduction in part count and process steps directly lowers manufacturing costs while maintaining 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
This solution ensures reliable rotational speed and angle information coupling, reduces manufacturing and assembly costs, and eliminates the need for special monitoring of slip, while providing a compact and precise angle measurement system suitable for safety laser scanners.
Implementation Method 1
a light beam generated by a laser periodically scans a surveillance area with the help of a deflection unit. The light is remitted to objects in the surveillance area
Implementation Method 2
encoders are provided for measuring the angle or speed of the rotating mirror or the motor driving the rotating mirror. These encoders have, for example, a line disc made of etched metal or laser-machined plastics. During the rotary movement, the markings on the graduated disk pass through a forked light barrier and thus generate a signal
Implementation Method 3
the distance of the object from the laser scanner is also determined from the travel time of light using the speed of light
Implementation Method 4
With phase-based methods, the transmitted light is modulated and the phase shift of the received light compared to the transmitted light is evaluated
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The laser scanner (10) has a light transmitter (12) for emitting a transmitted light beam (16), a rotating deflector (18) for periodic deflection of the transmitted light beam into the monitoring area (20), a light receiver (26) for generating a received signal from the objects and an angle dimensional scale (32). The deflector is integrally formed with the angle material measure. The deflector and the angle dimensional scale are formed as a plastic part. An independent claim is also included for a method for manufacturing a laser scanner.