Spherically Mounted Retroreflector with Shim-Ball Alignment
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Solution Overview
Problem
Existing retroreflectors, both solid glass and hollow prisms, face challenges in high-precision 3D position measurement due to refraction, dihedral angle errors, and non-planarity, leading to reduced measurement distance and increased complexity and cost in manufacturing.
Innovation Solution
A spherically mounted retroreflector design with a coupling element and carrier, allowing mechanical connection without adhesives, limiting translational movability along a single axis, and using a shim ball for precise alignment and temperature compensation, ensuring high planarity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hollow prism retroreflectors are built using molding process or gluing, then the retroreflector can be assembled, but the manufacturing process becomes complex and costly
Solution Approach 1:
The retroreflector and carrier are merged into a single integrated component. The retroreflector is formed as an integral part of the carrier body, eliminating the need for separate assembly steps such as molding or gluing. This reduces manufacturing complexity and cost while maintaining the functional requirements of the retroreflector.
2Manufacturing precision
If three reflective surfaces are precisely oriented to each other, then dihedral angle errors are minimized, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The three reflective surfaces are formed as integral parts of the carrier body through a single manufacturing process. This ensures precise orientation of the reflective surfaces relative to each other without requiring complex assembly steps. The geometric relationships are built-in during manufacturing rather than achieved through post-assembly alignment.
Solution Approach 2:
The carrier is designed with distinct geometric features including the retroreflector surfaces and coupling elements. By segmenting the functional requirements into specific geometric features of the integrated structure, precise orientation is achieved through the inherent geometry rather than through complex assembly procedures.
3Reliability
If retroreflector is mounted on a carrier for stability and protection, then the retroreflector is protected, but additional components increase manufacturing complexity
Solution Approach 1:
The carrier and retroreflector are merged into a single integrated component. The carrier body itself provides the protective structure and mounting function, while the retroreflector surfaces are formed as integral parts. This eliminates the need for separate mounting mechanisms and reduces the total number of components while maintaining stability and protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves cost-effective production with minimal dihedral angle errors and temperature-induced deformations, maintaining high precision and accuracy in interferometric measurements.
Implementation Method 1
Hollow prisms used as retroreflectors typically comprise three reflective surfaces, wherein incoming light is reflected back along the opposite direction (opposite with respect to an incoming direction) by the hollow prism. The reflection is in general provided through direct reflection at the three reflective surfaces of the hollow prism.
Data Source
AI summary
A spherically mounted retroreflector comprising an optic inlay, the optic inlay comprising a retroreflector having a vertex and an axis of symmetry, and a carrier having an at least partly spherical outer surface and a cavity, wherein the optic inlay is arranged in the cavity, and wherein the at least partly spherical outer surface has a sphere center, which sphere center coincides with the vertex, wherein the optic inlay is connected to the carrier. The optic inlay comprises a coupling portion, and the spherically mounted retroreflector comprises a coupling element arranged between the optic inlay and the carrier.