Leveling Plate Sensor Mount for XYZ Axis Alignment
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Solution Overview
Problem
Conventional sensor mounting methods fail to accurately align sensors with the XYZ axes of test assets, leading to errors and computational complexity in data collection, particularly for tri-axial accelerometers during vibration testing.
Innovation Solution
A sensor mounting device featuring a leveling plate with a level indicator and an alignment shelf that constrains sensor movement, allowing for precise alignment and adjustment along multiple axes, combined with a base structure for vertical positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sensor mounting methods are used, then the mounting process is simple, but the sensor alignment accuracy with respect to the XYZ axes deteriorates
Solution Approach 1:
A mounting plate is introduced as an intermediary device between the sensor and the test asset. The mounting plate includes a level indicator that serves as a mediator to establish accurate alignment with the XYZ axes, transferring the leveling function from the sensor itself to a dedicated mounting accessory.
Solution Approach 2:
The level indicator is pre-positioned on the mounting plate before sensor attachment. This preliminary alignment structure allows the sensor to be mounted in the correct orientation without requiring complex post-mounting calibration or adjustment procedures.
2Measurement precision
If conventional mounting methods are used, then the mounting process is quick, but data collection accuracy deteriorates due to misalignment errors
Solution Approach 1:
The level indicator on the mounting plate acts as a visual mediator that provides immediate feedback on alignment status. This eliminates the need for complex measurement and calibration procedures, allowing operators to quickly verify correct sensor orientation while ensuring high measurement precision.
3Ease of operation
If the sensor is mounted without alignment constraints, then the mounting operation is easy, but computational complexity increases due to error correction requirements
Solution Approach 1:
The mounting plate with level indicator preliminarily prevents alignment errors by providing visual guidance during the mounting process. This preliminary anti-action against misalignment eliminates the need for subsequent computational error corrections, simplifying both the mounting operation and data processing.
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
Ensures consistent and accurate sensor alignment, reducing errors and computational complexity in data collection by ensuring the sensor's axes are aligned with the test asset's axes, improving the reliability of data obtained during testing.
Implementation Method 1
a level indicator coupled to the leveling plate and visible from the front face of the leveling plate. The level indicator is operable for ensuring that the leveling plate is level in at least one axis with respect to the surface of the monitored structure.
Data Source
AI summary
A sensor mounting device and method to accurately mount a sensor to a test asset for data collection and component validation, the sensor mounting device including a leveling plate equipped with a level indicator, an alignment shelf adapted to constrain the movement of a sensor and hold the sensor level relative to the level indicator, and various protruding structures for aligning the mounting device with the test asset. The sensor mounting device may further include a base structure to support the leveling plate and allow a user to adjust the vertical position of the sensor to be mounted. The base structure may include a plurality of spanning members on which the leveling plate is mounted as to allow the leveling plate to be adjusted vertically.