Rotating Shaft Test Stand With Automatic Alignment Control
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Solution Overview
Problem
Existing test stands for rotatable test items, such as electric motors, require significant tooling time for mounting and aligning the test item shaft due to complex and time-consuming alignment processes.
Innovation Solution
A test stand equipped with a drive motor, a movable plate, sensors, and actors that work under the control of a unit to automatically align the test item shaft with the shaft of the test stand by measuring and correcting positional differences, utilizing sensors to minimize misalignments and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual alignment methods are used for mounting the test item to the test stand, then the alignment can be achieved, but considerable tooling time is required
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated system comprising sensors (e.g., laser sensors) that detect the position of the test item shaft, a control unit that processes the detected position data, and actuators that automatically adjust the movable plate to achieve precise alignment. This substitution of manual mechanical operations with an automated sensing-control-actuation system directly reduces tooling time while maintaining alignment precision.
Solution Approach 2:
The alignment system performs self-alignment through the automated interaction of sensors detecting shaft position, the control unit calculating required adjustments, and actuators executing the correction movements. The system serves itself by automatically compensating for positioning errors without requiring manual intervention, thereby eliminating the considerable tooling time previously needed for manual alignment operations.
2Productivity
If automated alignment is implemented using sensors and actuators, then tooling time is reduced, but device complexity increases
Solution Approach 1:
The patent implements automated alignment by substituting manual mechanical alignment with an integrated system of sensors (such as laser sensors), a control unit, and actuators. The sensors optically detect the position of the test item shaft, the control unit processes this data to determine misalignment, and the actuators automatically adjust the movable plate. This automation dramatically increases alignment speed and productivity, making the increased device complexity acceptable for high-throughput testing environments.
3Manufacturing precision
If precise alignment is achieved through automated correction, then alignment accuracy is improved, but the number of components increases
Solution Approach 1:
The patent implements a feedback-controlled alignment system where sensors continuously detect the position of the test item shaft, the control unit compares the detected position with the desired position, and actuators make real-time corrections to eliminate misalignment. This closed-loop feedback mechanism ensures high alignment precision by continuously monitoring and adjusting the position, justifying the increased number of components through the significant improvement in alignment accuracy.
Solution Approach 2:
The patent replaces imprecise manual alignment operations with an automated sensing and actuation system. Sensors (such as laser sensors) provide precise positional detection, the control unit performs accurate calculations to determine required corrections, and actuators execute precise movements of the movable plate. This substitution of manual operations with automated measurement and control systems directly improves alignment precision while accepting the necessary increase in system complexity.
Data Source
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AI summary
The invention relates to a test stand (1) and a method for testing a test item (2) having a rotatable test item shaft (13), the test stand (1) comprising: - a drive motor (3) and a shaft (4) driven by the drive motor (3), a rotational axis of the shaft (4) defining an axial direction (x), - a fixed plate (7), in which the shaft (4) is held by one, two or more bearings (5), the fixed plate (7) having a surface extending in a first radial direction (y) and in a second radial direction (z), - a movable plate (12) having a first surface bearing against the surface of the fixed plate (7), and a second surface opposite the first surface for mounting the test item (2) thereon, the movable plate (12) relative to the fixed plate (7), - one or more actors (17.1 to 17.3) configured to move the movable plate (12), - two or more sensors (19.1 to 19.3) configured to measure a position of the test item shaft (13) with regard to the radial directions (y, z), a control unit (23) configured to calculate a position of the test item shaft (13) based on the measurements of the sensors (19.1 to 19.3), and to control the actors (17.1 to 17.3) to correct the position of the movable plate (12) to reduce a difference between the calculated position and a set position.