Rotary Component Alignment Using Gyro and Accelerometer Sensors
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Solution Overview
Problem
Existing systems for aligning rotary components, such as motor and pump shafts, lack flexibility and user-friendly representation, particularly for vertically oriented setups, and struggle to accurately compute and display angular and offset errors in arbitrary orientations.
Innovation Solution
A measuring system utilizing accelerometers and gyros to detect component orientation, allowing for adaptable graphical representation on a display unit, enabling accurate alignment regardless of horizontal or vertical orientation, and providing enhanced user friendliness through precise angular and positional data computation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional light-based measuring units are used for alignment, then measurement capability is provided, but the system lacks flexibility for vertically oriented setups and arbitrary orientations
Solution Approach 1:
The patent applies universality by making the measuring system orientation-independent through the use of accelerometers and gyros that can detect positions in any orientation (horizontal, vertical, or arbitrary angles). The system universally handles all orientations by using gravity reference from accelerometers combined with rotational position detection from encoders, eliminating the need for orientation-specific measurement procedures.
2Productivity
If manual alignment by technician is used, then alignment can be performed, but the process is time-consuming and lacks automated computation of angular and offset errors
Solution Approach 1:
The patent applies self-service by enabling the measuring system to automatically compute angular errors and offset errors without requiring technician intervention for calculations. The system self-Service by processing measurement data through its control unit, which automatically determines misalignment parameters and provides corrective guidance, reducing the technician's role to simple data collection and interpretation.
3Measurement precision
If detector units alone are used for position determination, then rotational position can be detected, but the system cannot determine absolute orientation or distinguish between horizontal and vertical configurations
Solution Approach 1:
The patent applies merging by combining two different measurement approaches: accelerometers that detect absolute orientation relative to gravity, and encoders that detect rotational position changes. This combination merges absolute orientation data with relative position data to provide complete three-dimensional position information that is independent of the initial setup orientation.
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 system achieves flexible and accurate alignment of rotary components in various orientations, improving user experience by providing clear graphical and numerical feedback, ensuring optimal alignment and reducing misalignment-related issues.
Implementation Method 1
at least one of the accelerometers is adapted for detecting whether said rotary components are arranged with horizontal or vertical orientation
Implementation Method 2
Each of the measuring units also comprises a gyro
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a measuring system for measuring the relative positions of a first rotary component (3) and a second rotary component (5) relative to each other, comprising a first measuring unit (6) adapted for mounting on the first rotary component (3), and a second measuring unit (7) adapted for mounting on the second rotary component (5), wherein at least one of said measuring units (6, 7) comprises a detector unit for determining the positions of said rotary components (3, 5). According to the invention, at least one of said measuring units (6, 7) comprises a gyro (19a, 19b) for detecting the current angular position (α2) of said measuring unit (6, 7) at rotation of said rotary components (3, 5).