Noncontact Sensor Positioning for Faster Metrology Setup
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Solution Overview
Problem
Existing metrology systems lack the ability to automatically re-position non-contact sensors, such as optical sensors, relative to workpieces with different geometries, necessitating manual adjustment and slowing down the setup process.
Innovation Solution
A multi-directional positioning system that allows linear and rotational movement of sensors via motors with feedback control, enabling automatic positioning without operator intervention, accommodating various workpiece geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment of sensor positions is used, then device complexity is reduced, but setup time increases and productivity decreases
Solution Approach 1:
The system automatically determines sensor positions by detecting workpiece features and computing optimal locations, eliminating the need for manual operator intervention. The computer-controlled apparatus performs self-positioning through automated feature detection and coordinate calculation, thereby reducing setup time while maintaining manageable complexity through software automation.
Solution Approach 2:
The system pre-establishes a database of workpiece features and sensor position relationships. When a new workpiece is introduced, the system retrieves relevant feature data and pre-computes sensor positions based on stored geometric models, enabling rapid setup without manual measurement and positioning for each new part.
2Adaptability or versatility
If fixed sensor positions are used, then device complexity is reduced, but adaptability to different workpiece geometries deteriorates
Solution Approach 1:
The system transitions from fixed sensor positions to dynamic, programmable positioning. Sensors are mounted on computer-controlled mechanisms that can move to different locations based on detected workpiece features. This dynamic positioning capability allows the same apparatus to adapt to various workpiece geometries while keeping the physical hardware relatively simple through software control.
Solution Approach 2:
The positioning system is designed to handle multiple workpiece types and geometries using the same sensor apparatus. By combining feature detection, coordinate computation, and computer-controlled movement, a single universal system can accommodate different workpiece geometries that would otherwise require dedicated fixed-position systems for each part type.
3Productivity
If automated positioning systems are implemented, then productivity improves, but measurement precision requirements increase
Solution Approach 1:
The system incorporates feature detection that measures actual workpiece geometry and feeds this information back to the positioning control. The computer uses detected feature coordinates to compute and adjust sensor positions, ensuring high measurement precision even with automated positioning. This closed-loop feedback mechanism maintains accuracy while enabling automation.
Data Source
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.