Optical Spindle Error Detection Using Laser Displacement
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Solution Overview
Problem
Conventional methods for detecting spindle errors in powered machinery are costly and inefficient, particularly for aerospace applications, where thermal deformation causes accuracy deviations due to high-speed rotation, and existing dynamic detection methods using expensive instruments like LION TARGA III PCB are unaffordable and do not enhance processing accuracy.
Innovation Solution
An optical detecting apparatus comprising a standard bar with a rod lens and reflection face, and a sensor module with oblique laser heads and reflected spot displacement sensors, which calculates errors between the spindle and rotating platform by measuring displacement changes, allowing for precise detection of degree of freedom errors at a reduced cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive non-contact capacitive sensors (LION TARGA III PCB) are used for dynamic detection, then measurement precision is improved, but device cost increases significantly
Solution Approach 1:
The patent replaces expensive mechanical non-contact capacitive sensors with an optical detection system using lasers and position sensors. The optical system measures spindle errors by detecting the position of a standard bar through laser beams, substituting complex mechanical sensing with simpler optical measurement components that achieve comparable precision at lower cost.
Solution Approach 2:
The patent uses a standard bar as a physical copy or reference model of the spindle's ideal position. By measuring the deviation of the standard bar from its expected position using optical methods, the system indirectly measures spindle errors without requiring direct contact with the expensive capacitive sensors.
2Ease of manufacture
If static detection method with standard bar and dial indicator is used, then device cost is reduced, but measurement precision deteriorates due to assembly errors and inability to detect real rotation accuracy
Solution Approach 1:
The patent replaces the mechanical dial indicator system with an optical detection system using lasers and position sensors. This substitution eliminates the assembly errors inherent in mechanical contact methods and enables dynamic measurement during actual spindle rotation, maintaining low cost while significantly improving measurement precision.
Solution Approach 2:
The patent transitions from static detection (when the spindle is stationary) to dynamic detection (when the spindle is rotating). The optical system can measure spindle errors during actual operation, capturing real rotation accuracy rather than just static position, thereby improving measurement relevance and precision.
3Productivity
If high-speed rotation is performed to improve processing efficiency, then productivity is improved, but thermal deformation causes manufacturing precision to deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the optical detection system continuously measures spindle position errors during high-speed rotation. These measurements are fed back to identify thermal deformation patterns and accuracy deviations, enabling operators to compensate for thermal effects and maintain manufacturing precision despite high-speed operation.
Solution Approach 2:
The patent performs error detection and analysis during the processing operation itself rather than requiring separate measurement steps. By continuously monitoring spindle errors during high-speed rotation, the system identifies thermal deformation trends in real-time, allowing for immediate corrective actions to maintain precision without reducing productivity.
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 optical detecting apparatus provides a cost-effective means to detect six degrees of freedom errors, enhancing processing accuracy and mechanical precision in powered machinery, reducing the risk of thermal deformation-induced errors and improving the analysis of spindle errors under high-speed rotation conditions.
Implementation Method 1
The standard bar has a rod lens and a reflection face. The sensor module has two detecting groups, an oblique laser head, and a reflected spot displacement sensor. Each detecting group emits a laser light through the rod lens along the X-axis and the Y-axis of the powered machinery.
Implementation Method 2
The standard bar has a rod lens and a reflection face. The oblique laser head emits an oblique laser light to the reflected spot displacement sensor.
Data Source
AI summary
An optical detecting apparatus for detecting a degree of freedom error of a spindle and has a standard bar and a sensor module, and is assembled between a spindle and a rotating platform of a powered machinery. The standard bar has a rod lens and a reflection face. The sensor module has two detecting groups, an oblique laser head, and a reflected spot displacement sensor. Each detecting group emits a laser light through the rod lens along the X-axis and the Y-axis of the powered machinery. The oblique laser head emits an oblique laser light to the reflected spot displacement sensor. When the spindle of the powered machinery generates errors after rotating, the sensor module receives the changes of the laser lights to obtain the displacement change signals of the standard bar for a calculation unit to detect the errors between the spindle and the rotating platform.