Roughness Sensor Vibration Correction via Dynamic Capture
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Solution Overview
Problem
Existing roughness sensors are sensitive to vibrations, leading to measurement inaccuracies and are complex and expensive, making them unsuitable for manufacturing environments, and require extensive calibration and maintenance.
Innovation Solution
A method that captures dynamic vibrations of a roughness sensor using an additional measuring system with a data capturing rate greater than 100 Hz in the frequency range below 100 Hz, allowing for vibration correction and providing a compact, cost-effective roughness measuring apparatus by utilizing either dynamic tactile sensors or contactless distance sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a roughness sensor is made sensitive to capture fine surface details, then measurement precision is improved, but the sensor becomes highly sensitive to vibrations causing measurement inaccuracies
Solution Approach 1:
The patent introduces an intermediary measurement system (accelerometer or position change sensor) that measures vibrations separately. This intermediary system acts as a mediator between the roughness sensor and the vibrations, allowing the vibration data to be used for correcting the roughness measurements without directly affecting the sensor's sensitivity to surface details.
Solution Approach 2:
The patent implements a feedback mechanism where vibration measurements are continuously captured and used to correct roughness measurement values. The correction values are calculated based on the measured vibrations and fed back to adjust the roughness measurements, thereby compensating for vibration-induced errors in real-time.
2Reliability
If a vibration detector is added to the roughness sensor to capture vibrations, then measurement reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes the measuring device universal by enabling it to perform multiple functions: the same device can capture both roughness measurements and vibration measurements. This multi-functionality is achieved by integrating an additional measuring system that can operate in different measurement modes, reducing the need for separate dedicated vibration detectors.
Solution Approach 2:
The patent enables the measuring device to self-correct its measurements by using its own additional measuring system to capture vibration data and generate correction values. The device serves itself by internally processing the vibration data and applying corrections to the roughness measurements without requiring external vibration correction systems.
3Measurement precision
If a roughness sensor is designed for laboratory use with high precision, then measurement precision is improved, but ease of operation in manufacturing environments deteriorates due to vibration sensitivity
Solution Approach 1:
The patent changes the operational parameters of the measuring device by dynamically adjusting roughness measurement values based on measured vibration parameters. The system monitors vibration frequency and amplitude and applies corresponding correction factors, allowing the device to maintain precision across varying environmental conditions typical of manufacturing environments.
Data Source
AI summary
A method for capturing dynamic vibrations of a roughness sensor of a roughness measuring apparatus is provided. The movement of the roughness sensor relative to the roughness measuring apparatus and/or relative to a surface of a workpiece is captured by a measuring system in the frequency range below 100 Hz with a data capturing rate of greater than 100 Hz. The captured data of the relative movement are made available for further data processing in and/or stored. Moreover, a method for measuring the roughness of a workpiece surface is provided, in which the method for capturing the dynamic vibrations of a roughness sensor is used. In addition, a computer program product for controlling a roughness sensor of a roughness measuring apparatus in accordance with one of the methods is provided, and a roughness measuring device that is configured to carry out one of the methods.