Micro-tool Positioning Gauge for Needle Tip Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional micro-manipulator devices face challenges in precisely and efficiently positioning micro-tools due to the small size of inspection objects and delicate nature of micro-tools, leading to issues like needle tip damage and increased operational time, especially when using high-powered microscopes with narrow visual fields.
Innovation Solution
A method involving a positioning gauge that aligns a mark with the microscope's optical axis, allowing for the micro-tool to be attached after the gauge is removed, simplifying the positioning process and reducing direct contact with the inspection surface, thereby enhancing precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If direct positioning of micro-tool needle tip is performed using conventional methods, then positioning precision can be achieved, but the needle tip is at high risk of contact with dish surface causing damage or bending
Solution Approach 1:
The patent introduces a positioning gauge as an intermediary tool between the operator and the micro-tool needle tip. The gauge with its gauge surface and mark serves as a mediator to establish the correct positioning without requiring direct manipulation of the fragile needle tip near the dish surface, thereby preventing damage while achieving precision
Solution Approach 2:
The positioning gauge is used to pre-establish the correct position and orientation (mark aligned with optical axis) before the actual micro-tool operation begins. This preliminary positioning action separates the risky positioning step from the delicate needle tip, allowing precise setup without immediate risk to the needle
2Manufacturing precision
If high-powered microscope is used for precise positioning, then positioning accuracy improves, but the narrow visual field makes positioning harder and slower
Solution Approach 1:
The patent segments the positioning task into distinct components: the positioning gauge with its prominent mark handles the visual alignment aspect (easy to see even in narrow field), while the gauge surface handles the physical positioning reference. This segmentation allows the operator to use coarse visual cues from the mark rather than requiring full visibility of the entire needle tip in the narrow microscope field
Solution Approach 2:
The positioning gauge includes a mark (which can be visually distinct) that provides high-contrast visual feedback for alignment with the optical axis. This visual enhancement allows rapid detection of alignment status even through the limited visual field of high-powered microscopes, speeding up the positioning process
3Adaptability or versatility
If multiple kinds of micro-tools are used with varying shapes, lengths, and needle tip positions, then operational versatility is achieved, but positioning operation becomes harder and time-consuming
Solution Approach 1:
The positioning gauge serves as a universal reference tool that works with all different types of micro-tools regardless of their varying shapes, lengths, and needle tip positions. The gauge's mark and gauge surface provide a common reference framework that accommodates tool variety without requiring tool-specific positioning procedures, thus maintaining versatility while eliminating the need for repeated complex positioning operations
Solution Approach 2:
The patent changes the reference parameter from tool-specific features (needle tip position, shape characteristics) to gauge-based fixed parameters (mark position, gauge surface orientation). This parameter change allows consistent positioning methodology to be applied across different tool types, reducing positioning time despite tool variety
4Reliability
If careful positioning operation is performed to prevent needle tip contact, then needle tip damage is reduced, but the operation requires high skill and more time
Solution Approach 1:
The positioning gauge acts as an intermediary that simplifies the operation by providing clear visual and physical references (mark and gauge surface). Instead of requiring skilled manual dexterity to prevent needle tip contact, the operator simply needs to align the mark with the optical axis and position the gauge surface, making the protective function accessible to less skilled operators
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method for positioning a micro-tool (4) comprises: a positioning gauge positioning process (S1) including placing a gauge surface (5d) of a positioning gauge (5) at a needle tip position while the positioning gauge (5) is fixed to a holding part (30), and aligning a mark (5b) provided in the positioning gauge (5) with the optical axis (62a) of an objective lens (62); a positioning gauge focus adjustment process (S2) to focus on the mark (5b) in a state where the positioning gauge (5) has been positioned; and a micro-tool attachment process (S3) including fixing the micro-tool (4) to the holding part (30) after removing the positioning-gauge (5) from the holding part (30).