Optical Sensor Automatic Axis Alignment via Preliminary Scan
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Solution Overview
Problem
Wide-range optical sensors face challenges in accurately adjusting the optical axis for distant inspection targets, requiring cumbersome manual adjustments that are time-consuming and prone to errors.
Innovation Solution
An optical sensor system that includes a light-projecting element, an optical axis adjustment element, a light-receiving element, and a control unit, which allows for preliminary detection of a target object to set the detection direction automatically, eliminating the need for manual adjustments by using a specified condition to align the detection light and perform detection processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a wide-range optical sensor is used to detect distant targets, then the detection range is extended, but the optical axis becomes sensitive to angle errors causing deviation from the target section
Solution Approach 1:
The patent performs preliminary detection by scanning the detection light across the target object before final inspection. The control unit identifies the target section based on this preliminary scan and automatically adjusts the optical axis accordingly, eliminating the need for manual alignment while maintaining precision over extended ranges
Solution Approach 2:
The optical sensor system performs self-alignment by automatically adjusting its optical axis based on detection results from the target object. The control unit processes the detection signal and autonomously positions the detection light on the correct target section without requiring external manual intervention
2Measurement precision
If manual adjustment of the attachment fixture is performed to align the optical axis, then the optical axis alignment precision is improved, but the operation becomes cumbersome and time-consuming
Solution Approach 1:
The system performs automatic self-alignment by processing detection signals and autonomously adjusting the optical axis through the optical axis adjustment element, completely eliminating the need for manual loosening and tightening of the attachment fixture
Solution Approach 2:
The patent replaces the manual mechanical adjustment process with an automated control system that uses detection signals to drive the optical axis adjustment element, substituting mechanical operations with automated electronic control
3Length of stationary object
If the detection light is projected at a distant target object, then the detection range is extended, but slight angle errors cause the detection light to deviate from the target section
Solution Approach 1:
The control unit processes the detection signal returned from the target object and uses this feedback information to automatically adjust the optical axis. This closed-loop feedback mechanism ensures the detection light remains accurately positioned on the target section even at distant ranges
Solution Approach 2:
The system performs a preliminary scan to identify the target section before final detection. This preliminary action allows the control unit to pre-position the optical axis correctly, ensuring accurate detection light projection on the intended target section
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
Automatically sets the detection direction for the optical sensor, reducing the need for manual orientation adjustments and improving the efficiency of detecting distant targets by providing a visually recognizable notification projection and display of the inspection direction.
Implementation Method 1
a light-projecting element configured to project detection light
Implementation Method 2
a light-receiving element configured to receive the detection light reflected at a target object
Implementation Method 3
an optical axis adjustment element configured to adjust an optical axis of the detection light projected from the light-projecting element
Data Source
AI summary
An optical sensor includes a light-projecting element that projects detection light; an optical axis adjustment element that adjusts an optical axis of the detection light; a light-receiving element that receives the detection light reflected at a target object and outputs a detection signal; a reception unit that receives a specified condition relating to a detection result obtained via preliminary detection of a target object; and a control unit that sets, as an inspection direction, a direction of the detection light in which, of detection results based on the detection signal obtained by scanning a preliminary target placed in advance with the detection light by driving the optical axis adjustment element, a detection result corresponding to the specified condition is obtained, and drives the optical axis adjustment element to cause the detection light to be projected, in the inspection direction set, for an inspection target placed instead of the preliminary target.