Reference Master Assembly With Pivoting Trihedrons for Sensor Calibration
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Solution Overview
Problem
Existing calibration methods for optoelectronic sensors in mechanical part checking equipment are complex, costly, and require lengthy setup operations due to the need for complex reference master assemblies that adapt to varying mechanical part shapes and dimensions.
Innovation Solution
A simple and cost-effective reference master assembly comprising trihedrons with perpendicular plane reference surfaces, allowing for quick setup by adjusting their orientation to match the laser scanner's light plane, enabling efficient calibration without pre-defined orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex reference master assemblies are used to adapt to varying mechanical part shapes and dimensions, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The reference master assembly is divided into multiple independent trihedrons that can be separately manufactured and then assembled together. Each trihedron is a simple geometric element with three mutually perpendicular reference surfaces, and multiple such elements are arranged in known relative positions to create a complete calibration assembly that can handle complex measurement tasks
Solution Approach 2:
The trihedron-based reference master assembly serves multiple calibration functions and can be used with different types of optoelectronic sensors (laser scanners, cameras, etc.). The same simple trihedron structure can calibrate various sensor types and configurations, eliminating the need for specialized complex reference assemblies for each application
2Measurement precision
If complex reference master assemblies are used for calibration, then measurement precision is improved, but setup time increases
Solution Approach 1:
The trihedrons are pre-manufactured with precisely defined perpendicular reference surfaces and known relative positions. This preliminary manufacturing of standardized components eliminates the need for complex on-site assembly and calibration procedures, allowing rapid deployment of the reference master assembly while maintaining high measurement precision
Solution Approach 2:
Instead of creating custom complex reference assemblies for each calibration task, the invention uses replicated simple trihedron elements that can be quickly assembled in various configurations. These standardized copies can be rapidly set up and reconfigured for different calibration scenarios without time-consuming custom fabrication
3Ease of manufacture
If simple reference master assemblies are used, then ease of manufacture is improved, but adaptability to different mechanical parts deteriorates
Solution Approach 1:
The reference master assembly is designed as a dynamic, reconfigurable structure where simple trihedrons can be arranged in different configurations and positions. This allows the same simple components to adapt to various mechanical part geometries and calibration requirements, providing versatility without increasing manufacturing complexity
Solution Approach 2:
The calibration system achieves adaptability by changing the spatial parameters (positions and orientations) of the simple trihedron elements rather than changing the elements themselves. By adjusting how the trihedrons are arranged and positioned, the system can accommodate different mechanical part shapes and dimensions while keeping the reference elements themselves simple and easy to manufacture
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
Facilitates rapid and efficient calibration of optoelectronic sensors by allowing pre-manufactured trihedrons to be adjusted in-situ, reducing setup delays and costs while ensuring accurate three-dimensional measurements.
Implementation Method 1
Each of the laser scanners 2, 3 emits a light plane
Implementation Method 2
The shaped light line as seen by the checking device is digitized and interpreted as a succession of a plurality of points
Data Source
Figure 1~2
Figure 3
AI summary
A reference master assembly (7) for the calibration of a checking equipment for checking a mechanical part (1) which generates a three-dimensional numerical object corresponding to at least some portions of the mechanical part and includes optoelectronic sensors (2, 3) such as laser scanners that emits light planes on these portions of the mechanical part. The reference master assembly has a support body (8) and at least two trihedrons (T1, T2, T3), connected to it in mutually known positions, which define reference surfaces (4, 5, 6) on which the light planes are projected in the calibration phase. The trihedrons are connected to the support body with a pivoting coupling that allows the orientation of the reference surfaces to be adjusted in space. A method for setting the reference master assembly involves arranging the mechanical part to be checked in a checking position on a rotating support, orienting the optoelectronic sensors so that the light plane crosses the portions of interest of the mechanical part to be checked, arranging the reference master assembly in the checking position, adjusting the orientation of the trihedrons so that the light plane crosses the reference surfaces, and fixing the orientation of the trihedrons, before taking the reference master assembly to the metrology room for the certification of the configuration that is so defined.