Laser Alignment Modules for Fast Optoelectronic Array Setup
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Solution Overview
Problem
Existing manufacturing facilities face challenges in aligning optoelectronic arrays used in light curtain safety systems, which is crucial for ensuring safety and preventing machine activation during hazardous conditions.
Innovation Solution
The development of a pluggable alignment system comprising an alignment source module and an alignment indicator module, which are configured to be releasably coupled to optoelectronic arrays, facilitating near-alignment and enabling the generation of a light curtain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for optoelectronic arrays, then the alignment process becomes time-consuming and imprecise, but the system complexity remains low
Solution Approach 1:
The patent introduces an alignment tool as an intermediary device between the 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 alignment tool translates the invisible infrared alignment requirement into a visible guide, resolving the contradiction by providing both precision and speed without requiring complex automated systems.
Solution Approach 2:
The alignment tool uses visible laser light (typically green or red) to indicate the alignment state of the invisible infrared optoelectronic arrays. By converting the invisible alignment requirement into a visible color signal, operators can quickly and accurately align the arrays without time-consuming manual adjustment, thus improving both alignment precision and reducing alignment time.
2Manufacturing precision
If automated alignment systems are implemented, then alignment precision improves, but device complexity and cost increase
Solution Approach 1:
The alignment tool serves as a simple intermediary device that provides visual guidance without requiring complex automated control systems. It emits a visible laser beam that operators can use to manually align the arrays, achieving high precision alignment while keeping the system simple and cost-effective, thus resolving the contradiction between precision and complexity.
Solution Approach 2:
The alignment tool is a self-contained device that provides its own visible laser beam for alignment guidance. It does not require integration with complex automated control systems or additional infrastructure, allowing operators to perform precise alignment independently, thereby maintaining low system complexity while achieving high alignment precision.
3Ease of operation
If visible alignment aids are added to guide alignment, then ease of operation improves, but device complexity increases
Solution Approach 1:
The alignment tool introduces a simple visible laser beam as an intermediary aid that greatly enhances ease of operation. The laser provides clear visual guidance for aligning the invisible infrared arrays, making the alignment process intuitive and straightforward. The simplicity of the laser-based approach keeps the added complexity minimal while dramatically improving operational ease.
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 allows for rapid and guided alignment of optoelectronic units, reducing the need for manual guesswork and ensuring proper alignment for safety and operational efficiency.
Implementation Method 1
an alignment source module (ASM) configured to be releasably coupled to a first unit of a pair of optoelectronic arrays such that the ASM is oriented to emit an optical beam
Data Source
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.