Shimming Device Alignment Tool for Imaging Components
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Solution Overview
Problem
Current imaging device alignment technologies face challenges in achieving consistent and accurate alignment of components, leading to mechanical and imaging tolerance stacking issues, and manual adjustments are prone to variability between operators.
Innovation Solution
A shimming device with paired coupled protrusions and lower surface engaging portions on opposing sides, allowing for precise engagement with multiple surfaces to stabilize and align imaging device components, thereby standardizing the alignment protocol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment adjustments are performed, then alignment can be achieved, but operator variability causes inconsistency in alignment accuracy
Solution Approach 1:
The shimming device enables self-aligning through its engineered geometry. The paired protrusions on opposing sides automatically engage with corresponding recesses in the imaging device components, creating a self-correcting alignment mechanism that eliminates operator variability. The device serves itself to achieve precise alignment without requiring manual adjustment skills.
Solution Approach 2:
The invention changes the alignment parameters from manual positioning variables to fixed geometric parameters. By designing specific protrusion heights, angles, and positions, the system transforms alignment from an operator-dependent skill to a deterministic geometric constraint, ensuring consistent results across different operators.
2Manufacturing precision
If multiple components are aligned manually, then alignment can be achieved, but mechanical tolerance stacking leads to cumulative errors
Solution Approach 1:
The shimming device segments the alignment function into distinct geometric features (protrusions and recesses) that can be independently manufactured to tight tolerances. Each protrusion-recess pair acts as an independent alignment reference, preventing the cumulative stacking of tolerances that occurs when multiple components are manually aligned in sequence.
Solution Approach 2:
The alignment references (protrusions and recesses) are pre-engineered into the shimming device and imaging device components during manufacturing. This preliminary establishment of precise geometric relationships eliminates the need for subsequent manual alignment adjustments, thereby preventing cumulative tolerance errors from propagating through the system.
3Measurement precision
If alignment tools are designed for precision, then alignment accuracy improves, but device complexity increases
Solution Approach 1:
Instead of designing complex alignment tools that actively measure and adjust component positions, the invention inverts the approach by designing passive geometric constraints (protrusions fitting into recesses) that force alignment. This inversion simplifies the device structure while maintaining high precision, as the complexity is transferred to the manufacturing of the geometric features rather than the alignment mechanism itself.
Data Source
AI summary
A method of manufacturing a shimming device for engaging a plurality of surfaces is disclosed. In example embodiments, the method includes: (i) fabricating a first side of the shimming device, wherein the first side comprises: (a) a first plurality of pairs of coupled protrusions and (b) a first lower surface engaging portion; and (ii) fabricating a second side of the shimming device opposite the first side, wherein the second side comprises: (a) a second plurality of pairs of coupled protrusions and (b) a second lower surface engaging portion, wherein at least one pair of the first plurality of pairs of coupled protrusions engages a first surface of the plurality of surfaces when the second lower surface engaging portion engages a second surface of the plurality of surfaces.