Laser Alignment Modules for Optoelectronic Array Pre-Alignment
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Solution Overview
Problem
Existing manufacturing facilities face challenges in safely aligning optoelectronic arrays used in light curtain safety systems, which are crucial for preventing accidents by ensuring proper machine operation and worker safety.
Innovation Solution
The development of a pluggable alignment system comprising an alignment source module and an alignment indicator module, which are releasably coupled to optoelectronic arrays to facilitate near-alignment and precision alignment, thereby enabling the generation of a light curtain and ensuring safe machine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional alignment methods are used for optoelectronic arrays, then alignment can be achieved, but the process is time-consuming and lacks guidance
Solution Approach 1:
The patent introduces an alignment tool as an intermediary device between two optoelectronic arrays. This tool emits a visible laser beam that serves as a visual mediator, allowing operators to see and adjust the alignment between arrays. The tool includes alignment indicators that provide real-time feedback on alignment status, transforming an invisible optical alignment task into a visible, guided process.
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with optical alignment using a laser beam. Instead of relying on physical contact or mechanical fixtures to align arrays, the system uses a visible laser beam to indicate alignment status, allowing for non-contact, precise alignment guidance through optical means.
2Measurement precision
If manual alignment adjustment is performed without visual feedback, then alignment can eventually be achieved, but it requires extensive trial and error
Solution Approach 1:
The alignment tool incorporates visual feedback mechanisms including alignment indicators that illuminate or change state to indicate when the optical axes of two arrays are properly aligned. This real-time feedback allows operators to make precise adjustments without trial and error, directly observing when alignment is achieved and eliminating time-consuming guessing.
Solution Approach 2:
The alignment tool uses visible laser beams and potentially color-changing indicators to provide visual feedback on alignment status. The laser beam's visibility and any color changes in indicator lights transform an invisible alignment parameter into a visible, easily detectable signal that guides precise alignment.
3Manufacturing precision
If automatic alignment systems are used, then precision alignment can be achieved, but the arrays must first be manually pre-aligned
Solution Approach 1:
The alignment tool enables preliminary action by allowing operators to perform rough alignment using visual laser guidance before automatic alignment systems take over. This preliminary visual alignment reduces the initial misalignment between arrays, making the subsequent automatic alignment process more effective and reducing the complexity of getting the system to a state where automatic alignment can function properly.
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 alignment system allows for rapid and guided alignment of optoelectronic units, reducing the risk of accidents by ensuring proper alignment of light curtains, and enabling the use of automatic alignment systems for precision alignment.
Implementation Method 1
an alignment source module (ASM) configured to be releasably coupled to a first unit (110) of a pair of optoelectronic arrays such that the ASM is oriented to emit an optical beam (140)
Data Source
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AI summary
Apparatus and associated methods relate to an alignment system including an alignment source module (ASM) and an alignment indicator module (AIM) configured to be releasably coupled to a first unit and a second unit, respectively, of a pair of optoelectronic arrays. In an illustrative example, the ASM may be oriented, when coupled, to emit an optical beam in substantial alignment with a first optical axis of the first unit. The AIM may, for example, be configured, when coupled, to provide a visible indication when the optical beam is within a predetermined near-alignment orientation range relative to a second optical axis of the second unit. Each of the AIM and the ASM may, for example, be configured to axially couple along respective longitudinal axes of the first unit and the second. Various embodiments may advantageously facilitate manipulation of the pair of optoelectronic arrays into near alignment with each other.