Optical Shaft Alignment Camera with Scattering Surface
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Solution Overview
Problem
Existing shaft alignment measuring devices are complex, expensive, and lack flexibility, making them unsuitable for simple and cost-effective alignment measurements between mechanical elements.
Innovation Solution
A device utilizing a camera and a scattering surface, where the camera images the scattering surface to determine the alignment of mechanical elements, leveraging a camera such as a smartphone or compact camera, and a reflector arrangement to distinguish impact points of light beams, allowing for angular and parallel offset determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional shaft alignment measuring devices are used, then measurement precision is achieved, but device complexity and cost increase
Solution Approach 1:
The patent uses a camera to capture an image of a target structure on the opposite shaft, creating a visual copy of the target's position and orientation. This optical copying method replaces complex mechanical measurement systems while maintaining measurement precision through image analysis of the target structure at known angular positions
Solution Approach 2:
The patent replaces traditional mechanical alignment measurement systems with an optical imaging system using a camera and light source. The mechanical movement and contact-based measurement are substituted by optical fields and image processing, reducing device complexity while achieving the same measurement function
2Measurement precision
If traditional shaft alignment measuring devices are used, then measurement precision is achieved, but cost increases
Solution Approach 1:
The patent employs inexpensive, readily available components such as standard cameras and simple target structures instead of expensive specialized alignment instruments. The target structure can be a simple pattern or marking that does not require precision manufacturing, significantly reducing overall system cost while maintaining measurement capability
Solution Approach 2:
The patent uses a camera, which is a multi-functional device already widely available for other purposes (photography, video, etc.). This universal component performs the alignment measurement function without requiring a dedicated specialized instrument, reducing manufacturing and acquisition costs
3Measurement precision
If traditional shaft alignment measuring devices are used, then measurement capability is achieved, but flexibility decreases
Solution Approach 1:
The patent enables dynamic measurement by capturing images at different rotational angles of the shafts. The system can adapt to various measurement scenarios by taking images at any angular position, allowing flexible measurement of both static and dynamic alignment conditions without requiring physical reconfiguration of the device
4Measurement precision
If light beam impact point determination is used, then alignment measurement is achieved, but device complexity increases
Solution Approach 1:
Instead of directly detecting light beam impact points with complex optical detectors, the patent projects a light pattern onto a target structure and uses a camera to capture the optical copy (image) of this target. The position and orientation information is extracted from the captured image, simplifying the detection system while maintaining measurement precision
Solution Approach 2:
The patent introduces a target structure as an intermediary between the light source and the camera detector. This target serves as a mediator that converts the light beam interaction into a visible pattern that can be easily captured and analyzed by the camera, avoiding the need for complex direct impact point detection systems
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 solution provides a simple, flexible, and cost-effective method for determining shaft alignment by using a camera and scattering surface, enabling precise measurement of angular and parallel offsets with high accuracy and adaptability.
Implementation Method 1
a reflector arrangement (38) on the second measuring unit (18), in particular a mirror prism, onto which the light beam (28) is incident and by means of which the light beam (28) is reflected in the direction of the camera (36)
Implementation Method 2
a scattering surface (34) which is arranged in front of the camera (36) and onto which the light beam (28) is incident
Data Source
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AI summary
The invention relates to a device for determining the position of a first mechanical element (10) and a second mechanical element (12) relative to each other, comprising a first measuring unit (14) for attachment to the first mechanical element, a second measuring unit (18) for attachment to the second mechanical element, and an evaluation unit (22), wherein the first measuring unit has means (24) for generating at least one light beam (28, 30), a scattering surface (34) for scattering light (WV, PV) incident on the scattering surface, and a camera (36) for recording images of the scattering surface, wherein the second measuring unit has a reflector arrangement (38) which faces the first measuring unit when the measuring units are attached to the respective mechanical element in order to reflect the light beam (28', 28") onto the scattering surface, and wherein the evaluation unit is configuredto determine, from image data supplied by the camera, the impact position of the light beam reflected by the reflector arrangement on the scattering surface and from this the position of the first mechanical element and the second mechanical element relative to each other.