Optical Measurement System Self-Alignment via Monolithic Structure
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Solution Overview
Problem
Existing optical measurement systems require frequent and time-consuming calibrations due to tolerance-afflicted truncated cones, leading to systematic distance errors and misalignment issues, especially when the measurement setup differs from the original calibration.
Innovation Solution
The measurement system is aligned to an external mechanical reference coordinate system, ensuring an unambiguous relationship between the optical and mechanical coordinate systems, minimizing the need for additional alignments and calibrations by using a monolithic structural element with optomechanical components and precise mechanical means for positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical measurement systems use tolerance-afflicted truncated cones for illumination spot positioning, then the system can be manufactured with standard tolerances, but frequent calibrations and systematic distance errors occur
Solution Approach 1:
The patent replaces mechanical alignment and calibration procedures with an optical self-alignment mechanism. The illumination spot automatically defines the correct position on the measurement object through optical geometry, eliminating the need for mechanical coordinate system matching and reducing systematic distance errors caused by tolerance accumulation in mechanical assemblies.
Solution Approach 2:
The measurement system performs self-alignment through the optical path geometry. The illumination spot naturally converges to the correct position based on the optical components' arrangement, allowing the system to self-correct for manufacturing tolerances without requiring external calibration equipment or procedures.
2Measurement precision
If optical components are adjusted to achieve precise alignment, then measurement accuracy improves, but adjustment time and maintenance requirements increase
Solution Approach 1:
The optical components are pre-configured in a fixed geometric arrangement during manufacturing. The illumination optics and detection optics are positioned relative to each other such that the optical axis automatically passes through the correct measurement points, eliminating the need for time-consuming field adjustments and calibrations.
Solution Approach 2:
The patent combines the illumination path and detection path into a unified optical configuration where both functions share common reference elements. This merging ensures that alignment adjustments made for one function automatically benefit the other, reducing the total adjustment time and maintenance requirements.
3Adaptability or versatility
If mechanical reference coordinate systems are used for alignment, then the system can be mounted on various equipment, but coordinate system mismatches and misalignment issues occur
Solution Approach 1:
The optical measurement system is designed with a universal optical reference frame that can be mounted on various types of equipment (lathes, milling machines, grinders, etc.) without requiring equipment-specific calibration. The optical components reference themselves to the workpiece through the illumination spot, making the system adaptable to different machine tools and measurement applications.
Solution Approach 2:
The illumination spot acts as an intermediary between the optical coordinate system and the mechanical coordinate system of the measurement equipment. By defining the measurement origin through the optical path rather than through mechanical coordinate transformation, the system eliminates misalignment issues between different coordinate systems while maintaining versatility across equipment types.
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
This approach eliminates the need for frequent adjustments, reducing maintenance and making the system user-friendly by maintaining precise alignment and minimizing tolerance-afflicted issues in most measurement applications.
Implementation Method 1
the imaging components comprise at least one optomechanical light source as transmitting optics
Implementation Method 2
the image-recording components comprise at least one optomechanical sensor element as receiving optics
Implementation Method 3
the transmitting optics and receiving optics are configured for laser triangulation
Data Source
AI summary
A measurement system for optical measurement, in particular for measuring distance and/or position and/or speed and/or colour, defines at least one outer fixing point, which defines an outer coordinate system or lies therein, and at least one inner fixing point, which defines an inner coordinate system or lies therein. The two coordinate systems have a unique position relative to one another, which implies an adjustment or calibration of the system.