Optical Focus Trigger Sensor for Gear Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current measuring technologies, such as mechanical scanning and optical sensors, are inadequate for precise and efficient gear component measurements due to issues like slow measurement times, high costs, and limitations in accuracy and acceptance angles, making them unsuitable for in-line production monitoring.
Innovation Solution
A coordinate measuring device equipped with an optical, non-contact focus trigger sensor that uses a rotationally drivable holder and NC-controlled axes to perform relative feed and measuring movements, allowing for rapid and precise distance determination by emitting a switching signal when the nominal distance is reached, enabling quick and accurate measurements of gear components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical scanning with a stylus tip is used, then measurement accuracy is high, but measurement time is long and it is slow
Solution Approach 1:
The patent replaces the mechanical scanning system with a stylus tip with an optical measurement system using a laser triangulation sensor. The sensor emits a laser beam onto the gear tooth flank and detects the reflected light to determine surface geometry, eliminating mechanical contact while maintaining measurement capability. This substitution enables faster measurement speeds suitable for in-line production monitoring while achieving the required accuracy of 0.1-0.3 micrometers.
2Productivity
If optical sensors are used, then measurement speed is fast, but measurement accuracy is insufficient for gear measurement requirements
Solution Approach 1:
The patent implements a dynamic measurement approach where the gear component rotates during measurement, and the laser triangulation sensor tracks the tooth flanks at multiple positions. The measurement system dynamically adjusts the scanning path and integrates measurements from multiple angles and positions to achieve the required accuracy of 0.1-0.3 micrometers while maintaining fast measurement speeds for in-line production monitoring.
Solution Approach 2:
The patent extends the measurement from a single point to a two-dimensional surface scan by moving the laser beam across the tooth flank and rotating the gear. This multi-dimensional scanning approach allows the optical sensor to capture sufficient geometric information to achieve high measurement accuracy while maintaining rapid measurement capability.
3Measurement precision
If interferometric sensors are used, then measurement accuracy and resolution are very high, but measuring range is small and acceptance angle is narrow
Solution Approach 1:
The patent employs a laser triangulation sensor that can measure various gear parameters including tooth flank geometry, pitch, and other dimensional features. The sensor system is designed to handle different gear types and sizes, providing universal applicability for in-line production monitoring of various gear components while achieving the required measurement accuracy.
4Productivity
If laser triangulation sensors are used, then measurement speed is fast and detection angle is large, but measurement accuracy is not sufficient for gear measurements
Solution Approach 1:
The patent implements a dynamic measurement approach where the gear component rotates during measurement, and the laser triangulation sensor tracks the tooth flanks at multiple positions. The measurement system dynamically adjusts the scanning path and integrates measurements from multiple angles and positions to achieve the required accuracy of 0.1-0.3 micrometers while maintaining fast measurement speeds for in-line production monitoring.
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 device enables fast and accurate gear measurements, reducing measurement time from several minutes to under a minute, while maintaining high precision and being cost-effective, suitable for in-line production monitoring.
Implementation Method 1
the focus trigger sensor is arranged on the measuring setup in such a way that it is able to emit a light beam along an optical axis in the direction of an object plane of the gear component
Data Source
Figure 1~2
Figure 3~4
Figure 5~6A
AI summary
Coordinate measuring device (10) with a rotatable mount (13, 14) for a gear component (11) to be measured, a measuring setup and with several axes (X1, Y1, Z1, A1) designed to perform positioning and measuring movements of the measuring setup (17) relative to the gear component (11), wherein the measuring setup comprises: - an optical, non-contact switching sensor (20), o which is designed as a focus trigger sensor, wherein the focus trigger sensor is arranged on the measuring setup such that it is able to emit a light beam (LS) along an optical axis in the direction of the gear component (11), o wherein a scan movement relative to the gear component (11) can be performed with the focus trigger sensor using one or more of the axes (X1, Y1, Z1, A1), and o wherein the focus trigger sensor always a switching signal (s2) can be provided when the gear component (11) reaches a nominal distance relative to the focus trigger sensor.