Magnetized Foil Oscillator for High-Speed Optical Scanning
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Solution Overview
Problem
Existing optical scanning systems for elongated products in linear manufacturing processes are limited in their ability to simultaneously measure dimensional properties and surface integrity at high speeds, often requiring separate systems and failing to detect surface faults accurately due to lower scanning frequencies.
Innovation Solution
A high-frequency oscillating system with a magnetized foil supported by a torsion axis and synchronized high-frequency generators creates a magnetic field that drives the foil to oscillate at up to 20,000 cycles/sec, enabling a scanning frequency of 40,000 scans/sec for simultaneous dimensional and surface integrity measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate optical systems are used for dimensional measurements and surface integrity checking, then measurement coverage is complete, but system complexity increases and measurement speed decreases
Solution Approach 1:
The patent combines dimensional measurement and surface integrity checking into a single optical scanning system. The optical device scans both the dimensional properties (diameter) and surface profile (for faults like ridges, valleys, and bare patches) simultaneously using one light source and one scanning mechanism, eliminating the need for separate systems and reducing overall complexity while maintaining complete measurement coverage.
Solution Approach 2:
The optical scanning system is designed to perform multiple functions: it measures dimensional properties and detects surface faults simultaneously. The single optical device serves both as a dimensional measurement tool and a surface integrity inspection tool, making the system universal and adaptable to different measurement requirements without increasing complexity.
2Device complexity
If conventional scanning frequencies are used, then system simplicity is maintained, but measurement precision for surface faults deteriorates
Solution Approach 1:
The patent employs a dynamic scanning mechanism that oscillates at high frequencies (up to 20,000 cycles per second) to scan the product surface. This dynamic approach increases the scanning frequency significantly compared to conventional static or low-frequency systems, enabling the detection of surface faults with high precision while maintaining relative simplicity through the use of standard oscillating components.
Solution Approach 2:
The optical scanning system utilizes mechanical vibration at high frequencies to drive the scanning motion. The oscillating mechanism, supported by a torsion axis and driven by high-frequency generators, creates rapid back-and-forth motion of the optical beam across the product surface, enabling high-speed scanning that improves fault detection precision without requiring complex control systems.
3Productivity
If high scanning frequency is achieved through complex mechanisms, then measurement speed improves, but device complexity increases
Solution Approach 1:
The patent achieves high scanning frequency (up to 40,000 scans per second) through a mechanical vibration-based oscillating mechanism. The system uses a torsion axis supported foil or mirror that vibrates at high frequencies, driven by simple high-frequency electrical generators. This approach reaches measurement speeds of up to 20,000 cycles per second while keeping the scanning mechanism relatively simple, avoiding the need for complex robotic or computer-controlled positioning systems.
Solution Approach 2:
The patent replaces complex mechanical scanning systems with a simpler oscillating mechanism driven by high-frequency electrical generators. Instead of using complex motor-driven scanners or computer-controlled positioning systems, the invention uses electromagnetic excitation to generate high-frequency vibrations that directly drive the optical scanning element, reducing mechanical complexity while achieving high measurement speeds.
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 accurate, high-speed measurement of product diameter and surface profile, detecting faults like ridges, valleys, and bare patches with increased resolution, providing detailed fault analysis and enabling real-time data logging for quality control and diagnostic purposes.
Implementation Method 1
two high frequency generators (3, 4) with associated induction coils (5, 6) which create a magnetic field (7) which interacts with the magnetic foil (1)
Implementation Method 2
a magnetic field (7) which interacts with the magnetic foil (1) whereby the magnetic field of coil (5) is directed to the positive half of the foil (1) and the magnetic field of coil (6) is directed to the negative half of the foil (1)
Data Source
Figure 1~2
Figure 3~4.1
Figure 4.2~5
AI summary
A high speed oscillating system for non-contact optical scanning of an elongated product moving in a linear production process to determine the dimensional properties and surface profile integrity thereof, The system is designed to increase the scanning frequency and thereby the capability to measure the diameter or size of the product as well as its surface integrity and pick out flaws in the structure of the product in a manner which otherwise is not possible with present day systems on the market.