Laser Guide Rail Alignment for Automated Straightness Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing guide rails for linear rolling bearings often result in non-straight ends due to manual selection of support points and compressive forces, making automation difficult.
Innovation Solution
A method involving the production of a preform from steel, analysis of deviations, and laser irradiation of specific surface sections to induce precise shape changes without affecting the running tracks, allowing for automated correction of flexion and torsion in guide rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3-point alignment with manual support points and compressive forces is used, then guide rail straightness can be achieved, but automation is difficult and manual intervention is required
Solution Approach 1:
The patent replaces the conventional mechanical 3-point alignment system with a laser-based thermal field system. Instead of using mechanical supports and compressive forces, the invention uses a laser beam to heat specific regions of the guide rail, inducing thermal expansion and plastic deformation to correct straightness deviations. This substitution enables full automation while achieving the desired manufacturing precision.
Solution Approach 2:
The invention changes the physical state and temperature parameters of the guide rail material by applying localized laser heating. By controlling the laser power, heating duration, and scan speed, the patent induces controlled thermal expansion and phase changes in the material, enabling automated correction of geometric deviations without mechanical contact.
2Productivity
If laser irradiation is applied to correct shape deviations, then automation is enabled and productivity increases, but there is a risk of affecting the hardness and shape of the running tracks
Solution Approach 1:
The patent applies laser irradiation selectively to specific regions of the guide rail that require straightness correction, while deliberately excluding the hardened running track surfaces from the laser beam path. By controlling the laser scan areas and parameters, the invention achieves localized shape correction without compromising the hardness, microstructure, or geometric precision of the running tracks.
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
Enables the production of highly accurate, straight guide rails through automated processes, reducing manual intervention and ensuring the hardness and shape of the running tracks are preserved.
Implementation Method 1
irradiating the preform held in the holding device with a laser beam, a surface section being irradiated with the laser beam along the longitudinal axis at a plurality of locations
Implementation Method 2
it is heated into the plastic range, the surface section being arranged outside the at least one running track
Implementation Method 3
Stresses are consequently created in the guide rail, which lead to precisely the desired shape change of the preform
Implementation Method 4
the irradiated surface section cools relatively rapidly after the laser beam is turned off because the heat energy is dissipated into the remaining material of the preform
Implementation Method 5
the heat energy is dissipated into the remaining material of the preform, where it causes only a small temperature increase
Data Source
AI summary
A method includes producing a preform of a guide rail from steel, putting the preform in a holding device so that the preform is held fixed in position, analyzing the preform held in the holding device, a deviation from a straight shape being measured at a plurality of locations along the longitudinal axis. The method further includes irradiating the preform held in the holding device with a laser beam, a surface section being irradiated with the laser beam along the longitudinal axis at a plurality of locations, respectively on one of two side surfaces facing in opposite directions in relation to the first transverse axis, in such a way that it is heated into the plastic range.