Interposer Tool for Optical Runout Measurement on Rotating Shafts
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Solution Overview
Problem
Existing precision optical measuring instruments struggle to accurately measure surfaces perpendicular to the rotational axis, requiring additional calibration and synchronization with touch probes, which introduce system synchronization issues.
Innovation Solution
An interposer device with a probe configured for movement along the rotational axis, allowing an optical system to image the illuminated profile of the probe, which varies along the direction of the rotational axis, enabling direct contact and measurement of perpendicular surfaces using an optical sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch probe is used to measure surfaces perpendicular to the rotational axis, then measurement capability is improved, but system complexity and synchronization issues increase
Solution Approach 1:
The patent replaces the mechanical touch probe system with an optical measurement system. The interposer device with geometric features is imaged by the optical imaging system, allowing measurement of surfaces perpendicular to the rotational axis through optical means rather than mechanical contact. This substitution eliminates the synchronization and calibration issues between mechanical and optical systems while maintaining measurement precision.
Solution Approach 2:
The interposer device serves as an intermediary element between the workpiece and the optical imaging system. By attaching the interposer with known geometric features to the workpiece, the system can indirectly measure surface variations through changes in the interposer's apparent geometry in the optical images, avoiding the need for direct mechanical probing.
2Measurement precision
If a touch probe is used for secondary measurement, then runout measurement capability is improved, but calibration requirements and synchronization issues worsen
Solution Approach 1:
The optical imaging system with interposer replaces the touch probe for runout measurements. The interposer's geometric features are imaged during workpiece rotation, and runout is determined by analyzing variations in the interposer's apparent position or geometry in the optical images, eliminating calibration and synchronization time requirements.
Solution Approach 2:
The interposer device with precisely manufactured geometric features serves as its own reference standard. The known geometry of the interposer features provides an inherent reference that eliminates the need for separate calibration procedures, as the interposer self-defines the measurement reference frame.
3Productivity
If profile view imaging is used, then optical measurement speed is improved, but information about perpendicular surfaces is lost
Solution Approach 1:
The interposer device introduces a new dimensional reference into the profile view images. By attaching the interposer with features extending in the axial direction (perpendicular to the imaging plane), the system can extract surface height and runout information from the apparent position or geometry of these features in the 2D profile images, effectively adding measurement capability in a direction perpendicular to the traditional imaging plane.
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 interposer device enables precise measurement of surface variations perpendicular to the rotational axis without the need for additional calibration, providing accurate runout measurements through direct contact and optical imaging, eliminating synchronization issues.
Implementation Method 1
an optical system imaging an illuminated profile of the probe
Implementation Method 2
an optical system imaging an illuminated profile of the probe
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An optical system (10) for measuring a surface (110, 110a, 110b) of a workpiece (100), the system comprising: an optical measuring instrument having a rotary system for rotating a workpiece (100) about a rotational axis (108), a lighting system (40, 56) for illuminating the workpiece (100), a measurement system (50) for measuring surfaces (110) of the workpiece (100), a computer (60), and a device (120c) for contacting a first surface (110, 110a, 110b) of the workpiece (100), the device (120c) having a first probe (140) having a detection zone (166) and a contact surface point (152, 152c) for directly contacting the first surface (110, 110a, 110b) of the workpiece (100). The measurement system (50) includes an optical sensor (54) configured to image (112, 156) at least a portion of the detection zone (166) to determine a displacement of the first probe (140) as the contact surface point (152, 152c) maintains contact with the first surface (110, 110a, 110b) of the workpiece (100) when the workpiece (100) is rotated (360) about a rotational axis (108).