Non-contact Sensor Integration on Functional Testing Platform
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Solution Overview
Problem
Current methods for dimensional inspection of gears require separate functional and analytical testing, which are time-consuming and space-intensive, and non-contact optical methods lack the accuracy and efficiency of tactile probes.
Innovation Solution
Integration of at least one non-contact sensor, such as a laser, on a functional testing platform allows for simultaneous or independent analytical and functional measurements, combining the benefits of both methods on a single machine, enabling faster and more accurate data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate functional and analytical testing machines are used for gear inspection, then measurement accuracy and reliability are maintained, but device complexity and space requirements increase
Solution Approach 1:
The patent combines functional testing and analytical testing capabilities into a single integrated machine platform. The system merges the functional testing mechanism (with master gear and test gear meshing) and analytical testing mechanism (with non-contact optical sensors) into one unified platform, eliminating the need for separate machines while maintaining measurement accuracy through coordinated operation of both testing modes.
Solution Approach 2:
The integrated machine platform performs multiple functions: it can conduct functional testing to evaluate gear assembly performance, analytical testing to measure individual gear tooth geometry, and both modes can operate simultaneously or independently. This multi-functionality allows a single device to replace multiple specialized machines.
2Loss of information
If separate functional and analytical testing are performed, then comprehensive measurement data is obtained, but measurement time and productivity decrease
Solution Approach 1:
The system enables continuous measurement by allowing functional and analytical testing to occur simultaneously or in seamless sequence on the same platform. The non-contact optical sensors can capture analytical data during the functional testing process itself, eliminating idle time between measurements and maintaining continuous useful action throughout the inspection cycle.
Solution Approach 2:
The integrated platform prepares both functional and analytical testing capabilities in advance, with sensors and measurement systems pre-positioned and calibrated. This preliminary preparation allows immediate commencement of comprehensive measurements without setup delays, improving productivity while ensuring complete data collection.
3Productivity
If non-contact optical sensors are used instead of tactile probes, then measurement speed increases, but measurement precision and reliability decrease
Solution Approach 1:
The patent replaces traditional mechanical tactile probes with non-contact optical sensors for analytical measurements. This substitution eliminates mechanical contact, reducing measurement forces that could deform soft gear materials and enabling faster data collection. The optical sensors capture gear tooth geometry through light reflection and imaging, providing both speed and accuracy.
Solution Approach 2:
The system changes the measurement parameter from mechanical contact force to optical reflection characteristics. By measuring how light reflects off gear tooth surfaces rather than using physical probe contact, the system achieves faster measurement speeds while maintaining precision through sophisticated optical analysis algorithms that compensate for surface variations.
4Measurement precision
If traditional tactile probe methods are used for analytical testing, then measurement accuracy is maintained, but cycle time and space requirements increase
Solution Approach 1:
The patent replaces mechanical tactile probe measurement systems with non-contact optical sensing. This substitution eliminates the need for slow, sequential point-by-point mechanical scanning and enables parallel optical capture of multiple gear tooth features simultaneously, dramatically reducing cycle time while maintaining measurement accuracy through advanced optical 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
This approach significantly reduces cycle time and space requirements while providing accurate measurements of gear characteristics, achieving faster data collection and improved precision compared to traditional methods.
Implementation Method 1
at least one non-contact sensor, such as a laser
Data Source
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AI summary
A method and machine comprising at least one non-contact sensor (52) on a functional testing platform (50) for workpiece inspection and/or measurement. The inclusion of at least one non-contact sensor on the functional testing platform results in the combination of two machine platforms into a single machine and provides the user with measurement characteristics of both methods, functional and analytical, saving significant cycle time and significant space.