Optical Sensor for Five-Axis Structural Deviation Measurement
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Solution Overview
Problem
Current methods for measuring structural deviations in working machines from five reference axes are either economically impractical, require complex installations, or lack precision, especially for multi-axis calibration, with existing systems being ineffective for simultaneous calibration across all axes.
Innovation Solution
A non-contact measuring system comprising a main sensing body with annularly disposed sensor elements and a lighting unit that revolves around the machine's axis, allowing for high-resolution detection of structural deviations in two or three dimensional displacements, using a laser light source and a dynamo to radiate light vertically onto the sensor elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If interometer calibration is used for working machine, then measurement capability is provided, but installation becomes complicated
Solution Approach 1:
The patent replaces complex mechanical interometer calibration systems with an optical measurement system. A light source projects light onto a measurement surface, and a sensor detects the reflected light to determine structural deviations. This optical substitution eliminates complicated mechanical installations while maintaining measurement precision for multi-axis calibration.
2Adaptability or versatility
If multi-reference axes measuring system is used, then linear axes measurement is possible, but cost increases and precision remains poor
Solution Approach 1:
The patent employs sensor elements arranged in multiple dimensions (X, Y, Z axes) to achieve multi-axis measurement capability. By configuring sensors to detect light reflection from different angular perspectives and combining measurements from multiple sensor elements, the system achieves precise measurement of structural deviations across five reference axes simultaneously, rather than requiring separate systems for each axis.
3Productivity
If conventional measuring techniques are used, then calibration can be performed, but simultaneous calibration in five reference axes is not achieved
Solution Approach 1:
The patent merges multiple measurement functions into a single integrated system. The light source, measurement surface, and multiple sensor elements work together to simultaneously measure structural deviations across five reference axes in one calibration operation. This unified approach enables simultaneous multi-axis calibration, dramatically improving productivity while maintaining precision through the coordinated operation of all components.
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
Enables easy, cost-effective, and precise measurement of structural deviations with high-resolution optical signals, improving the accuracy and efficiency of working machine calibration without the need for complex installations.
Implementation Method 1
a lighting unit, which being entrained on a working platform of the working machine, has a light source
Implementation Method 2
the main sensing body is able to detect a working machine's structural deviation from five reference axes when receiving an error signal from the lighting unit
Data Source
AI summary
Means for measuring a working machine's structural deviation from five reference axes includes a main sensing body bonded with a main axis of the working machine (or controlled to revolve), and a lighting unit set around the main sensing body to circle about the main sensing body with a fixed radius (or the lighting unit radiates a light on the main sensing body from that radial distance and circles along with the main sensing body) such that as soon as the main sensing body has detected an optical signal, it is converted to an error signal informing of the working machine's structural deviation in two or three dimensional displacement.