Optical Machine Geometry Monitoring System
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Solution Overview
Problem
Existing machine geometry monitoring systems face challenges in accurately compensating for environmental effects and long-term drifts in harsh shop floor environments, requiring frequent and time-consuming calibration processes that are impractical for inline measurements.
Innovation Solution
A machine geometry monitoring system that uses a calibration monitoring unit with optical sensors to periodically sense deviations in machine geometry, allowing for real-time compensation of temperature and other environmental influences, and dynamic properties, enabling quick and accurate monitoring of machine geometry changes without the need for multiple measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If frequent calibration using reference ball scans is performed to compensate for environmental effects and machine drift, then measurement accuracy is improved, but measurement time and operational complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical reference ball scanning method with an optical measurement system. An optical artifact is used instead of physical reference balls, and optical sensors detect the artifact's position to determine machine geometry deviations. This substitution eliminates the time-consuming mechanical scanning process while maintaining accuracy compensation capability.
Solution Approach 2:
The patent creates an optical copy/representation of the machine geometry state through the optical artifact. Instead of physically measuring the machine structure directly, the system uses an optical artifact that reflects the current geometric state, allowing rapid non-contact measurement of machine deviations without physical contact with the machine structure.
2Measurement precision
If traditional calibration methods are used to monitor machine geometry changes, then accuracy compensation is achieved, but the process becomes cumbersome and impractical for inline measurements in harsh shop floor environments
Solution Approach 1:
The patent replaces complex mechanical reference ball scanning with a simplified optical measurement system. The optical artifact and optical sensors provide a more straightforward measurement approach that can be easily integrated into automated measurement cycles, eliminating the need for manual reference ball handling and scanning operations.
Solution Approach 2:
The system enables self-service calibration monitoring where the optical artifact automatically reflects the machine's current geometric state. The measurement system itself provides the calibration information needed for accuracy compensation without requiring external reference standards or manual intervention, making the process autonomous and simpler to operate.
3Measurement precision
If multiple sequential measurements are performed to derive calibration maps, then measurement accuracy is improved, but measurement speed and productivity decrease
Solution Approach 1:
The patent uses an optical artifact that creates an optical copy of the machine geometry state. This allows simultaneous capture of multiple geometric parameters in a single measurement event, eliminating the need for sequential measurements. The optical system captures the complete calibration information in one operation, dramatically increasing measurement speed while maintaining accuracy.
Solution Approach 2:
The patent transitions from sequential one-dimensional measurements to simultaneous multi-dimensional optical measurement. The optical sensor array captures position information in multiple dimensions simultaneously, allowing the system to derive complete calibration maps from a single measurement event rather than requiring multiple sequential scans.
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 system effectively minimizes geometric deviations by providing a low-frequency global surveillance mechanism, allowing for quick and accurate compensation of non-repeating effects, enhancing machine accuracy and reducing the need for frequent reference ball scans, thereby improving measurement precision and efficiency.
Implementation Method 1
a calibration monitoring unit with an optical, at least two-dimensional measuring location sensing unit... configured with at least one light source and at least one two dimensional optical sensor to derive an at least two dimensional location information of a shadow of at least one artifact
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3a~3e
AI summary
The invention relates to a machine state monitoring system (2) for recurrently determining a change in static and/or dynamic properties of a geometry of a machine (1). The machine (1) is configured with positional encoders (4) to derive a coordinate information of at least a first machine portion (5) with respect to a second machine portion (3), which are movable with respect to one another by a motorized drive unit (13). According to the invention, the monitoring system (2) comprises at least one calibration-monitoring-unit (6) with an optical, at least two-dimensional measuring location sensing unit which is fixed to the first machine portion (5) and configured to optically sense an at least two dimensional location information of an artifact (3) which is provided at the second machine portion (3), and which artifact is temporarily moved into a sensing range of the calibration-monitoring-unit (6) for determining the change in the static and/or dynamic properties of the geometry of the machine (1) by a comparison of multiple of such sensings, in particular multiple times in the course of a regular operation of the machine. The monitoring system (2) is therein configured to update compensation parameters of a model or map of the geometry of the machine (1) which is used to derive the coordinate information from the encoders (12).