Rotating Laser Angle Measurement with Calibration Error Correction
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Solution Overview
Problem
Existing angle measurement devices, particularly those used in sheet metal bending machines, face challenges in achieving high accuracy due to manufacturing and orientation tolerances, which are difficult to minimize without complex mechanical adjustments, limiting their precision and increasing costs.
Innovation Solution
A compact angle measurement device with a continuously rotating directional rotor, a light transmitter, and a receiver, which uses a calibrating unit and error model to correct for device-specific errors, allowing for contactless angle determination between workpiece surfaces without the need for mechanical adjustments, thereby improving measurement accuracy and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional laser diodes with integrated monitor diodes are used for compact angle measurement, then device compactness is improved, but measurement precision deteriorates due to manufacturing tolerances and component orientation errors
Solution Approach 1:
The patent transforms the measurement approach by changing from direct geometric measurement to a parameter-based correction method. It introduces calibration parameters and error models that account for manufacturing tolerances and component orientation deviations, allowing the system to achieve high measurement precision despite using compact, miniaturized components with inherent tolerances
Solution Approach 2:
The patent replaces mechanical adjustment mechanisms with a software-based error correction system. Instead of using complex mechanical adjustments to compensate for manufacturing tolerances, it uses calibration procedures that determine error parameters, which are then used to correct measurements through mathematical models, eliminating the need for precision mechanical alignment
2Ease of operation
If miniaturized components are used to achieve compact device design, then ease of operation is improved, but manufacturing precision deteriorates due to unavoidable tolerances in small components
Solution Approach 1:
The patent implements a self-calibration and self-correction mechanism. The device automatically determines calibration parameters through a calibration procedure and uses these parameters to correct its own measurement errors. This self-service approach allows the device to compensate for its own manufacturing imperfections without requiring external adjustment or higher precision manufacturing
Solution Approach 2:
The patent performs preliminary calibration to determine error parameters before actual measurement operations. By conducting the calibration procedure in advance, the system establishes correction parameters that are then applied during normal operation, allowing the device to achieve high accuracy despite the inherent imprecision of miniaturized components
3Measurement precision
If complex mechanical adjustments are implemented to improve measurement accuracy, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical adjustment systems with a software-based error correction approach. Instead of implementing multiple mechanical adjustment mechanisms to compensate for errors, it uses calibration procedures that determine error parameters and applies mathematical corrections to the measurements, significantly reducing mechanical complexity while maintaining or improving measurement precision
Solution Approach 2:
The patent extracts and separates the error compensation function from the mechanical structure. By taking out the error correction capability and implementing it as a software-based calibration and correction system, the patent eliminates the need for complex mechanical adjustment mechanisms, simplifying the overall device architecture
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 device achieves enhanced measurement accuracy of up to 0.1° by modeling and correcting device-specific errors, reducing the need for mechanical adjustments and lowering production costs while maintaining a compact design suitable for hand-held applications.
Implementation Method 1
as a laser transmitter a semiconductor laser diode is used
Implementation Method 2
Light reflected from the surfaces towards the rotating mirror is directed from the rotating mirror via a semi-permeable mirror to a light-sensitive sensor
Implementation Method 3
as a light-sensitive sensor a monitor diode is used which is integrated in the semiconductor laser diode... responds to incoming laser light
Data Source
AI summary
A device for determining an angle between two workpiece surfaces, comprising a transmitter for producing a light beam, a continuously rotating directional rotor for emitting the produced light beam in a rotating emission direction perpendicular to an axis of rotation of the directional rotor, a receiver for receiving a reflected light beam when the emitted light beam is reflected antiparallel to the emission direction by one of the two workpiece surfaces, an emission angle sensor unit for determining emission angles of the emitted light beam at which the receiver receives the reflected light beam, a calibrating unit for determining at least calibration parameters, a memory unit for storing the calibration parameters and an error model, and an evaluation unit configured to determine the angle as a function of the determined emission angles of the light beam emitted by the directional rotor, the stored calibration parameters and the stored error model.