Optical Inspection Calibration Carrier for Repeatable Alignment
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Solution Overview
Problem
Existing optical inspection devices in automated assembly machines struggle to ensure precise alignment and calibration of assembly elements, leading to waste and increased production costs due to improperly aligned components.
Innovation Solution
A test system with a carrier having fixed holders for assembly elements, ensuring consistent alignment and secure fastening, combined with a transport device for repeated inspection, allows calibration and compensation of the inspection device's parameters based on acquired deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If assembly elements are held in fixed positions during inspection, then measurement precision is improved, but device complexity increases due to the carrier and holder structure
Solution Approach 1:
The patent uses a carrier with holders that replicate the actual assembly positions and orientations. The holders are designed to hold assembly elements in the same relative positions as they will be assembled, creating a simplified copy of the assembly configuration that enables precise optical measurement without requiring the full assembly machine structure
2Manufacturing precision
If assembly elements are securely fastened to prevent movement, then manufacturing precision is improved, but ease of operation worsens due to additional fastening steps
Solution Approach 1:
The holders are designed with dynamic fastening mechanisms that allow quick release and replacement of assembly elements. The clamping elements can be rapidly opened and closed to secure or release elements, enabling fast element replacement while maintaining secure fastening during inspection to ensure precise alignment measurements
3Reliability
If the inspection device is calibrated using fixed assembly elements, then reliability is improved, but loss of time increases due to repeated positioning and securing operations
Solution Approach 1:
The carrier with holders is pre-configured with assembly elements secured in their exact assembly positions before inspection begins. This preliminary positioning and securing of elements in the correct configuration allows the optical inspection device to be calibrated reliably without requiring repeated positioning operations during the calibration process itself
Solution Approach 2:
The carrier structure serves multiple functions: it holds assembly elements in precise positions for inspection, maintains consistent orientation for repeated measurements, and can be reused for both calibration and actual assembly operations. This multi-functionality eliminates the need for separate calibration fixtures, reducing overall time loss
Data Source
AI summary
A test system for an optical inspection device of an automated assembly machine. The test system includes a carrier for holding at least one assembly element to be assembled, and a transport device for transporting the carrier into a test position and into a rest position away from the test position. The optical inspection device can be assigned or is assigned to the test position. The carrier includes a first holder for a first assembly element and a second holder for a second assembly element, wherein the holders are fixedly disposed relative to one another on the carrier.