Shaft Scanning System with Encoder Position Tracking
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Solution Overview
Problem
Highly precise and efficient 3D measurement of long and narrow shafts and similar structures is challenging due to the limited range and narrow angle of optical scanners, requiring multiple scan positions and time-consuming movement of the scanner along the shaft.
Innovation Solution
A scanning system comprising a support structure with a mounted scanner, a fixed guide, and an encoder to measure distance, along with optional stabilizers and inertial measurement units, allowing the scanner to move continuously along the shaft while maintaining accurate positional data through correlation of encoding and scanning data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a laser scanner with long range is used, then the scanning distance is improved, but the measurement density decreases due to narrow optical path angle
Solution Approach 1:
The scanning process is divided into multiple sequential scan positions along the shaft. The scanner is moved to different locations (first scan position, second scan position, etc.) to capture measurements at various segments of the shaft, ensuring adequate measurement density throughout the entire structure despite the narrow optical path angle at any single position
2Manufacturing precision
If multiple scan positions are performed, then the measurement completeness is improved, but the scanning time increases
Solution Approach 1:
The manual or mechanical process of moving the scanner between multiple positions is replaced with an automated support structure system. The support structure (including cable, rod, or rail configurations) automatically transports the scanner along the shaft, reducing manual intervention time and enabling more efficient sequential scanning at multiple positions
Solution Approach 2:
The system incorporates automatic position tracking and data correlation capabilities. The encoder automatically records the position of the scanner at each scan location, and the processing system automatically correlates measurements from different scan positions, eliminating the need for manual position recording and data integration
3Area of stationary object
If the scanner is moved along the shaft, then the coverage area is improved, but the operational complexity increases
Solution Approach 1:
The support structure is designed to provide multiple functions: it supports the scanner during scanning operations, transports the scanner between positions, and incorporates encoding mechanisms for position tracking. This multi-functional design consolidates what would otherwise require separate systems into a single integrated unit, reducing overall operational complexity
Data Source
AI summary
Scanning systems and methods for measuring shafts are described. The scanning systems include a support structure and a scanner mounted to the support structure, at least one fixed guide arranged such that the support structure is configured to move along the at least one fixed guide, at least one positional guide arranged such that at least one positional guide is connected to the support structure to guide movement of the scanner along the at least one fixed guide, and an encoder operably coupled to the at least one positional guide and configured to measure, at least, a distance from the encoder to the support structure.