Inner Surface Shape Measurement Probe Alignment and Calibration
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Solution Overview
Problem
Existing inner surface shape measurement devices face challenges in accurately and easily aligning probes with small holes in workpieces, leading to potential collisions and requiring skilled operators for magnification calibration, especially when the working distance is minimal.
Innovation Solution
An inner surface shape measurement device with a workpiece rotation unit, a probe adjustment unit, and a controller that acquires and adjusts probe posture information from multiple positions to align the probe coaxially with the rotation axis, and a magnification calibration method using a calibration standard with a cylindrical surface and flat surface to associate probe output signals with calibrated displacement amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment by skilled operator is used, then alignment accuracy is improved, but automation is reduced and operator skill dependency increases
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical measurement system. The probe alignment unit uses optical detection to automatically determine probe position and posture, eliminating the need for skilled operators to perform manual alignment while maintaining high alignment accuracy through automated feedback control.
Solution Approach 2:
The system performs self-alignment through automated detection and adjustment. The probe alignment unit automatically detects probe position deviations and controls the probe drive unit to correct the alignment, enabling the system to perform alignment operations autonomously without human intervention.
2Productivity
If probe is inserted into small hole with minimal working distance, then measurement capability is improved, but collision risk increases
Solution Approach 1:
The patent implements a feedback control system where the probe alignment unit continuously monitors probe position and posture, and the controller adjusts probe movement based on this feedback. This closed-loop control enables precise positioning within small holes while preventing collisions by detecting and correcting position deviations before they cause damage.
Solution Approach 2:
The system performs preliminary alignment operations before probe insertion. The probe alignment unit pre-adjusts probe position and posture to ensure proper alignment with the small hole, and the system calculates safe movement paths in advance, preventing collisions before they occur during the measurement process.
3Measurement precision
If magnification calibration is performed manually with visual checking, then calibration accuracy is improved, but operator skill requirement increases and operation time is extended
Solution Approach 1:
The patent replaces manual visual checking during magnification calibration with automated optical measurement. The probe measures the calibration standard's dimensions automatically, and the system calculates magnification factors through computational processing, eliminating the need for operators to visually monitor and manually adjust while reducing calibration time.
4Measurement precision
If probe alignment is performed manually with microscope observation, then alignment precision is improved, but ease of operation is reduced and skill dependency increases
Solution Approach 1:
The system performs self-alignment through automated detection and correction. The probe alignment unit automatically detects probe position deviations from the rotation axis and controls the probe drive unit to correct the alignment, enabling non-skilled operators to achieve high alignment precision without manual microscope observation.
Data Source
AI summary
The inner surface shape measurement device, which measures an inner surface shape of a small hole formed in a workpiece, includes: a rotating body for rotating the workpiece around a rotation axis, and a linear-and-tilting-motion stage; an elongated probe capable of being inserted into the small hole of the workpiece; a probe linear-and-tilting-motion mechanism capable of adjusting posture of the probe; a camera, configured to be rotatable integrally with the rotating body, for imaging the probe from at least three circumferential positions on a rotation trajectory centered on a rotation axis; and a controller for adjusting the posture of the probe using the probe linear-and-tilting-motion mechanism based on an image taken by the camera at each of the circumferential positions.