Noncontact Sensor Positioning for Adaptive Gear Measurement
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Solution Overview
Problem
Existing gear inspection systems, particularly those using non-contact sensors, lack the ability to automatically re-position sensors relative to workpieces with different geometries, requiring manual adjustment and limiting measurement accuracy and efficiency.
Innovation Solution
A multi-directional positioning system that allows linear and rotational movement of non-contact sensors, such as lasers, to automatically adjust their position relative to workpieces, enabling precise measurement without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning of non-contact sensors is used, then device complexity is reduced, but measurement precision and setup time are worsened
Solution Approach 1:
The system performs self-calibration by automatically determining the sensor's actual position and orientation through measurement of known reference features on the workpiece, eliminating the need for complex manual positioning mechanisms and operator intervention
Solution Approach 2:
The patent replaces complex mechanical positioning systems with a computational approach where the sensor position is determined through mathematical calculations based on measured reference features, substituting physical adjustment mechanisms with algorithmic positioning
2Adaptability or versatility
If sensors are fixed in position, then device complexity is reduced, but adaptability to different workpiece geometries is worsened
Solution Approach 1:
The system transitions from a static fixed sensor position to a dynamic positioning system where the sensor can be automatically repositioned and recalibrated for different workpiece geometries through motorized adjustment mechanisms and software control
Solution Approach 2:
The positioning system is designed to handle multiple workpiece types and geometries through a universal calibration procedure that can identify and adapt to various reference feature configurations, making the system versatile without requiring geometry-specific fixtures
3Productivity
If manual adjustment of sensor position is required, then ease of operation is improved, but productivity is worsened
Solution Approach 1:
The system automatically performs sensor positioning and calibration without operator intervention by measuring reference features, calculating the required adjustments, and executing the repositioning autonomously, significantly reducing setup time and improving productivity
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
Facilitates faster setup times and improved measurement accuracy by allowing sensors to be positioned accurately and efficiently for different workpiece geometries, enhancing the measurement process.
Implementation Method 1
A non-contact probe emits light on the tooth surface of a gear at a desired location to determine the same deviation
Data Source
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AI summary
A multi-axis system (30) for positioning a workpiece measuring sensor (54) on a metrology machine. Preferably, each sensor is positionable via a system comprising movement along and/or about at least linear directions/axes (X, Z, A, B) so as to control linear and/or rotational movement of a sensor automatically to a predetermined position without operator intervention. The multi-axis positioning system allows faster setup times when a workpiece or tooling on a machine is changed.