Sensor Alignment via Wobbling Cylindrical Section
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Solution Overview
Problem
Existing sensor alignment methods in industrial environments require separate adjustment processes for each spatial direction, making the alignment process cumbersome and time-consuming due to the need for multiple fastening and tightening steps.
Innovation Solution
A wobbling motion mechanism in the sensor's cylindrical section allows simultaneous alignment in two spatial directions using crowned lock nuts and a shim washer, enabling precise and reproducible alignment by specifying the alignment in polar coordinates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate adjustment processes are used for each spatial direction, then the sensor can be aligned in each direction, but the alignment process becomes cumbersome and time-consuming
Solution Approach 1:
The patent combines multiple adjustment functions into a single adjustment plate that allows simultaneous alignment in multiple spatial directions. The adjustment plate integrates elongated holes arranged in different orientations, enabling the sensor to be adjusted in both horizontal and vertical directions through one unified component rather than separate adjustment mechanisms.
Solution Approach 2:
The patent introduces a two-dimensional adjustment capability within a single plane by arranging elongated holes in different orientations on the adjustment plate. This allows the sensor to perform wobbling motion in two spatial directions simultaneously, transforming a multi-step sequential adjustment process into a single-plane multi-directional adjustment.
2Reliability
If multiple fastening elements are used for alignment in different directions, then the sensor can be secured in each direction, but the fastening process becomes complex and time-consuming
Solution Approach 1:
The patent uses a single adjustment plate that combines multiple adjustment functions for different spatial directions. Instead of requiring separate fastening elements for each directional adjustment, the adjustment plate with its multi-oriented elongated holes allows one fastening element to secure the sensor after multi-directional alignment is achieved.
Solution Approach 2:
The adjustment plate serves multiple functions simultaneously: it provides alignment in horizontal directions, vertical directions, and enables wobbling motion adjustment. This universal component replaces what would otherwise require multiple specialized adjustment mechanisms and fastening elements.
3Measurement precision
If separate adjustment processes are performed for each spatial direction, then precise alignment can be achieved, but the number of adjustment steps increases
Solution Approach 1:
The adjustment plate merges multiple adjustment capabilities into a single component that can be adjusted in one operation. The elongated holes are arranged to provide adjustment ranges in multiple spatial directions, allowing the installer to achieve precise alignment in both horizontal and vertical directions simultaneously rather than through separate adjustment steps.
Data Source
Figure 1
Figure 2
AI summary
The sensor (1) has a hollow cylindrical housing (2) accommodating components that are arranged on a cylindrical section with a fastening screw (6). Two spherical locking nuts (4, 5) are attached to the screw. The screw and a spacer (8) are supported between the nuts in the cylindrical section. A tilt position of the cylindrical section is adjusted by tightening the nuts against the screw and fixing the spacer. The nuts exhibit respective convex curved outer surfaces (4a, 5a). The curved outer surfaces comprise a certain radius of curvature and form a spherical surface or an aspherical surface.