Laser Tracker Warm-Up Control via Thermal Feedback
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Solution Overview
Problem
Laser trackers face significant challenges in rapidly warming up and stabilizing, leading to inefficiencies and potential measurement inaccuracies due to thermal drift and the lack of automated mechanisms for determining when the instrument is ready for use, especially when not kept continuously powered on.
Innovation Solution
An automated method using temperature sensors, a heat source, and a processor to control electrical current based on temperature profiles, ensuring the laser tracker reaches a stable equilibrium temperature quickly and accurately, with additional diagnostic tools for tracking stability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser tracker is kept continuously powered on to avoid warm-up time, then the productivity is improved, but the energy consumption increases
Solution Approach 1:
The system performs preliminary warming up actions by applying electrical current to heat sources before measurements are needed. The processor monitors temperature sensors and determines when the instrument has reached sufficient warmth, allowing the tracker to be quickly ready for use without requiring continuous operation. This resolves the contradiction by preparing the system in advance only when necessary.
Solution Approach 2:
The laser tracker system monitors its own temperature through integrated sensors and automatically determines when it has warmed up sufficiently for accurate measurements. The processor uses temperature data from multiple sensors to assess the thermal state of different components and decides when the instrument is ready, eliminating the need for continuous operation while maintaining measurement readiness.
2Use of energy by moving object
If the laser tracker is powered off to save energy, then the energy consumption is reduced, but the warm-up time increases when turned on again
Solution Approach 1:
When the laser tracker is powered on, the system immediately begins preliminary warming actions by activating heat sources and applying electrical current. The processor monitors temperature sensors and determines when sufficient warmth has been achieved, allowing the tracker to become operational quickly after being powered off. This reduces the penalty of shutdown by rapidly preparing the system when needed.
Solution Approach 2:
The system dynamically adjusts the warming process based on real-time temperature feedback from sensors. The processor modifies the electrical current applied to heat sources according to the thermal state of different components, optimizing the warm-up speed while minimizing energy consumption. This dynamic control allows quick recovery from shutdown without excessive energy use.
3Device complexity
If manual monitoring of temperature and stability is used, then the device complexity is reduced, but the measurement precision decreases due to thermal drift
Solution Approach 1:
The system implements feedback by continuously monitoring temperature through multiple sensors and using this information to determine when the laser tracker has stabilized. The processor analyzes temperature data from various components and decides when the instrument is ready for accurate measurements. This automated feedback mechanism ensures measurement precision without requiring complex manual monitoring procedures.
Solution Approach 2:
The laser tracker system automatically monitors its own thermal state using integrated temperature sensors and determines when it has reached sufficient stability for accurate measurements. The processor uses temperature feedback to assess the thermal condition of different components and autonomously decides when the instrument is ready, maintaining measurement precision without adding significant complexity.
4Productivity
If the laser tracker components are heated rapidly to reduce warm-up time, then the productivity is improved, but the reliability decreases due to thermal shock
Solution Approach 1:
The system dynamically controls the heating process by adjusting the electrical current applied to heat sources based on real-time temperature feedback from sensors. The processor monitors the thermal state of different components and modifies the heating rate to prevent thermal shock while maintaining efficient warm-up. This dynamic control allows rapid warming without compromising instrument stability or reliability.
Solution Approach 2:
The system changes the heating parameters (electrical current level, duration) based on the thermal state of the instrument. The processor uses temperature sensor data to determine appropriate heating levels, increasing heat application when components are cold and reducing it as they approach target temperatures. This adaptive parameter control enables fast warm-up while preventing thermal shock and maintaining reliability.
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 approach significantly reduces the warm-up time, ensures high accuracy, and provides a reliable method for determining when the tracker is ready for measurements, minimizing user error and downtime.
Implementation Method 1
a heat source configured to convert electrical energy to thermal energy
Implementation Method 2
temperature sensors configured to detect a thermal state of the laser tracker
Data Source
AI summary
A method for warming up a first instrument that includes providing an instrument measuring a first instrument temperature with the first temperature sensor at a starting time; measuring a first air temperature with the second temperature sensor at the starting time; determining a first profile based at least in part on the first instrument temperature and the first air temperature, the first profile representing an amount of first electrical current applied as a function of time, the first profile selected to provide a predicted level of instrument performance within a warm-up time; applying the first electrical current according to the first profile; and providing an operator at the starting time with a numerical value for the warm-up time of the instrument, wherein the warm-up time is based at least in part on the first instrument temperature and the first air temperature.