Automatic Leveling Device Using Auxiliary and Main Sensor Phases
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Solution Overview
Problem
Current automatic leveling devices require multiple tilt sensors with different accuracy levels, leading to a complex structure and increased manufacturing costs, as they struggle to perform high-accuracy leveling over a wide range with a single sensor.
Innovation Solution
An automatic leveling method and device utilizing a single tilt sensor with auxiliary and main leveling mechanisms, where the auxiliary leveling adjusts the base plate's tilt within a predetermined surplus of the maximum range, allowing for accurate leveling beyond the sensor's detection range, and updating the absolute position based on each leveling result.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high accuracy tilt sensor is used to achieve high accuracy leveling, then the leveling precision is improved, but the detection range of the tilt angle becomes narrow
Solution Approach 1:
The leveling process is divided into two distinct phases: auxiliary leveling for coarse adjustment over a wide tilt angle range, and main leveling for precise adjustment within the sensor's detection range. This segmentation allows the system to leverage the wide range of the normal tilt sensor and the high precision of the high-accuracy tilt sensor in their respective optimal operating domains.
Solution Approach 2:
The auxiliary leveling is performed as a preliminary step before the main leveling. By first using the normal tilt sensor to bring the base plate within the detection range of the high-accuracy tilt sensor, the system prepares the conditions for subsequent high-precision leveling, ensuring that the expensive high-accuracy sensor operates only in its optimal range.
2Measurement precision
If multiple tilt sensors with different accuracy levels are used to cover both high accuracy and wide range, then the leveling performance is improved, but the device complexity increases
Solution Approach 1:
The system dynamically switches between two tilt sensors based on the current tilt angle and operational phase. The control unit determines which sensor to use at any given moment, transitioning from the normal tilt sensor during auxiliary leveling to the high-accuracy tilt sensor during main leveling. This dynamic allocation optimizes performance while managing complexity.
Solution Approach 2:
The control unit serves multiple functions: it manages both auxiliary and main leveling processes, switches between two different tilt sensors, and coordinates the leveling mechanism. This multi-functional design consolidates control logic into a single unit, reducing overall system complexity despite using multiple sensors.
3Measurement precision
If multiple tilt sensors are used to achieve both coarse and precise leveling, then the leveling capability is improved, but the manufacturing cost increases
Solution Approach 1:
The leveling function is segmented into auxiliary leveling (using normal tilt sensor) and main leveling (using high-accuracy tilt sensor). This segmentation allows the system to use cheaper sensors for the majority of the adjustment range and reserve the expensive high-accuracy sensor for the final precise positioning, reducing overall component costs.
Solution Approach 2:
The normal tilt sensor performs partial leveling (auxiliary leveling) to bring the system within the operational range of the high-accuracy sensor. This partial action by a cheaper sensor prevents the need for the expensive sensor to operate across its entire potential range, optimizing the cost-performance ratio of the sensor system.
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 highly accurate leveling over a wide range using a single tilt sensor, simplifying the structure and reducing costs by allowing the device to operate effectively beyond the sensor's detection range without the need for multiple sensors.
Implementation Method 1
a tilt sensor capable of detecting a horizontality with high accuracy is provided
Data Source
AI summary
The invention provides an automatic leveling device comprising; one tilt sensor provided on a leveling base plate, a leveling mechanism unit capable of tilting the leveling base plate in at least two directions and a control device for controlling the leveling mechanism unit and for tilting the leveling base plate, wherein the control device is configured to tilt the leveling base plate so that the tilting of the leveling base plate follows a searching route as set in a process of a leveling from a condition where a tilt detecting signal from the tilt sensor is not obtained, carries out an auxiliary leveling to obtain signals from the tilt sensor in a process of changing the tilting, and carries out a main leveling by controlling the leveling mechanism unit based on the detection result from the tilt sensor where a tilt detecting signal is obtained from the auxiliary leveling.