Automated Motor Axle Alignment Using Optical Sensing
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Solution Overview
Problem
The manual alignment of motor axles in testing platforms is time-consuming and labor-intensive, requiring expertise and resulting in potential measurement errors due to lack of automation in the centering process.
Innovation Solution
An automatic mounting and demounting device for motor testing platforms, featuring a multi-axis motion unit and a positional information sensing member, which includes image and distance sensors to generate positional data for precise alignment and connection of motor and testing apparatus axles, allowing for automated centering and reduced preparation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment is used to center the motor under test, then the alignment can be adjusted by an experienced worker, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical alignment system with an automated optical sensing system. Image sensors capture images of the motor axle and testing apparatus axle, and a control host processes these images to automatically calculate and execute alignment adjustments, eliminating the need for manual mechanical adjustment while maintaining high precision
Solution Approach 2:
The system enables self-service alignment through automated image capture, processing, and adjustment execution. The control host automatically processes images from the image sensors, calculates alignment parameters, and controls the motion units to adjust positions without human intervention, making the system self-sufficient in the alignment process
2Reliability
If manual alignment is used, then expertise can ensure correctness, but significant manpower is required
Solution Approach 1:
The patent replaces manual expertise-based alignment with an automated image processing system. The control host executes algorithms to process images and calculate alignment parameters automatically, ensuring consistent correctness without requiring operator expertise, thereby simplifying operation while maintaining reliability
3Productivity
If automated mounting and demounting is implemented, then time and manpower are reduced, but the device complexity increases
Solution Approach 1:
The patent employs a multi-functional control host that integrates image processing, alignment calculation, and motion control functions. The image sensors serve multiple purposes including capturing axle positions and verifying alignment. This multi-functionality reduces the need for separate dedicated components, managing system complexity while achieving full automation
Solution Approach 2:
The patent introduces image sensors as an intermediary between the physical alignment state and the control system. These sensors capture visual information and convert it into processable data, serving as a mediator that enables automated detection and control without requiring direct mechanical sensing or complex human intervention
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
The solution enables efficient, precise, and automated axis centering, reducing manpower and time required for motor testing preparations, enhancing the ease of use and accuracy of motor testing platforms.
Implementation Method 1
the image sensor being adapted to obtain an image data attributed to the upright wall having a marking information
Implementation Method 2
the distance sensor being adapted to obtain a distance data about a distance between the distance sensor and the upright wall
Data Source
AI summary
An automatic mounting and demounting device and system for a motor testing platform, adapted to enable a control host to control automatic mounting and demounting between an axle of a motor under test and an axle of a testing apparatus, includes a mobile platform and a positional information sensing member. The control host controls the mobile platform according to positional information generated by the positional information sensing member, such that a carrier for carrying the motor under test is automatically driven to a corresponding position to thereby effect alignment and connection or separation of the axle of the motor under test and the axle of the testing apparatus. Therefore, preparation for the motor dynamics testing is automatically carried out effectively and correctly, thereby reducing the time and manpower required for testing-related preparation.