Non-Contact Positioning Device with Laser Sensor and Overshoot Correction
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Solution Overview
Problem
Conventional positioning devices face challenges in achieving high precision and speed due to contact sensing methods, which can cause physical damage and limit measurement accuracy, especially for minute shapes, and long distance measurement sensors have resolution limitations that hinder precise positioning in electric discharge machining.
Innovation Solution
A non-contact positioning device using moving means and length measuring means to detect objects within a predetermined range, automatically correcting for overshoot and storing coordinate values for precise positioning without collision risks, enabling high-speed and high-precision operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact sensing method is used for positioning, then positioning precision can be achieved, but measuring time increases due to decreased approach speed to suppress physical damage and impact
Solution Approach 1:
The patent replaces the mechanical contact sensing method with a non-contact optical sensing method using a laser displacement sensor. The laser sensor detects the position of the workpiece surface by measuring the reflected light, eliminating the need for physical contact between the probe and the workpiece. This substitution allows for high-speed approach without risk of physical damage while maintaining measurement precision through optical detection.
2Measurement precision
If contact sensing probe is made with increased rigidity to suppress deformation, then positioning precision is maintained, but the spherical portion size increases making measurement of minute shapes impossible
Solution Approach 1:
The patent replaces the mechanical contact probe with a non-contact laser displacement sensor that uses optical fields instead of physical contact. This eliminates the need for a rigid spherical probe tip, allowing the sensing point to be effectively point-sized with no physical dimensions that would prevent measurement of minute shapes. The optical sensing method can detect surface positions of extremely small features without the geometric constraints of a physical probe.
3Adaptability or versatility
If long distance measurement laser displacement sensor is used, then non-contact measurement of minute objects is enabled, but measurement precision is insufficient with resolution of 10 μm and error of about 0.2 mm
Solution Approach 1:
The patent controls the distance between the laser displacement sensor and the workpiece surface to be within a predetermined range, optimizing the measurement dimension. By maintaining the sensor within close proximity to the workpiece, the system achieves both non-contact measurement capability and high precision, as the laser sensor's resolution improves significantly at shorter distances while still avoiding physical contact.
Solution Approach 2:
The patent changes the operating parameters of the laser displacement sensor by controlling the measurement distance to be within a specific range. This parameter optimization allows the sensor to operate in its high-precision mode, achieving resolution suitable for electric discharge machining positioning while maintaining non-contact measurement advantages.
4Measurement precision
If high precision laser length measuring machine is used, then measurement error is suppressed below 5 μm, but the measurable range is restricted to about 10 mm±1 mm making practical direct use difficult
Solution Approach 1:
The patent uses a standard laser displacement sensor that can function both as a high-precision measurement device and as a positioning sensor within the machining system. By controlling the sensor distance to be within a predetermined range, the system achieves high measurement precision suitable for electric discharge machining while maintaining the ability to measure various workpiece sizes and shapes, thus providing universal applicability.
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 allows for precise positioning at high speeds without collision risks and enables direct measurement of minute shapes, improving measurement precision and reducing errors, facilitating accurate additional work without the need for offline measurement and reinstallation.
Implementation Method 1
length measuring means for measuring the distance to the positioning object in non-contact manner
Data Source
AI summary
A positioning device includes a driver which moves a positioning object and a sensor which measures the distance to the positioning object in a non-contacting manner and outputs a detection signal if the positioning object is detected only in a length measuring area within a predetermined range from any detection position, shaft controller which stops the driver by detecting the detection signal from the sensor and automatically correcting for an overshoot amount between the stop position and any detection position, when the driver moves the positioning object and the sensor, and the positioning controller that stores the coordinate value after the automatic correction by the shaft controller and that performs the positioning based on the reference coordinate value.