Sensor Positioning Adjustment Support System for Sub-Millimeter Deviation Detection
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Solution Overview
Problem
Existing technologies face challenges in efficiently detecting and adjusting for minute positional deviations of sub-millimeters or less in manufacturing equipment, due to limitations in sensor positioning and posture determination.
Innovation Solution
An adjustment support system that includes an arithmetic unit and a storage unit, which generates and determines multiple sensor positions and postures for detecting positional deviations by analyzing sensor and imaging target information, thereby reducing man-hours for adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor position and posture is determined based on hidden area computation, then the device complexity is reduced, but the measurement precision of minute positional deviations (sub-millimeters or less) deteriorates
Solution Approach 1:
The patent divides the measurement task into multiple sensor positions and postures rather than using a single position. By segmenting the measurement into multiple viewpoints, the system can detect minute positional deviations that would be undetectable from a single position, thereby improving measurement precision without significantly increasing overall system complexity.
Solution Approach 2:
The patent transitions from single-position measurement to multi-position measurement by adding the dimension of multiple sensor positions and postures. This dimensional expansion allows the system to capture positional deviations in three-dimensional space from multiple angles, enabling detection of sub-millimeter deviations that cannot be detected from a single viewpoint.
2Measurement precision
If manual search for sensor position and posture is performed, then measurement precision can be ensured, but the loss of time for adjustment increases
Solution Approach 1:
The patent performs preliminary computation to determine optimal sensor positions and postures before actual measurement. By pre-calculating the necessary viewing angles and positions based on the target object's geometry, the system eliminates time-consuming manual trial-and-error adjustment while ensuring measurement precision is achieved from the first attempt.
Solution Approach 2:
The system automatically determines optimal sensor positions and postures through computational algorithms without requiring manual intervention. The computation unit self-services by calculating the necessary measurement viewpoints based on target object information, thereby reducing adjustment time while maintaining measurement accuracy.
3Ease of operation
If sensor position and posture are determined without computing magnitude of positional deviation, then the ease of operation is improved, but the reliability of detection deteriorates
Solution Approach 1:
The patent incorporates feedback by computing the magnitude of positional deviation for each candidate sensor position and posture. This feedback mechanism allows the system to evaluate whether a given position can actually detect the required deviation magnitude, thereby ensuring detection reliability while maintaining ease of operation through automated evaluation.
Solution Approach 2:
The patent replaces manual mechanical adjustment with computational determination of sensor positions. By substituting the mechanical trial-and-error process with computational algorithms that calculate optimal positions based on deviation magnitude requirements, the system maintains ease of operation while ensuring detection reliability through mathematical validation.
Data Source
AI summary
An adjustment support system comprises an arithmetic unit and a storage unit. The storage unit stores sensor information including features of a sensor that captures an image of a target, and imaging target information including dimensions, shape, and disposition of an imaging target of the sensor, and the arithmetic unit generates a plurality of candidates for an imaging position and posture of the imaging target by the sensor, and determines whether or not positional deviation of the imaging target in a plurality of directions is detectable from a captured image obtained by the sensor based on the sensor information and the imaging target information, with respect to each of the plurality of candidates for the imaging position and the imaging posture. The arithmetic unit then determines an imaging position and posture for the sensor to actually capture an image of the target from the plurality of candidates.