Test Indicator Angle Correction for Measurement Accuracy
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Solution Overview
Problem
Users of test indicators may fail to obtain correct measurement results due to neglecting the importance of maintaining the gauge head parallel to the measurement surface and often forget or omit correcting measurements for non-parallel angles, leading to significant errors in unevenness measurements.
Innovation Solution
A test indicator equipped with a rotary encoder, display unit, and correction unit that calculates and applies a correction coefficient based on the angle between the gauge head and measurement surface, automatically correcting measurement values to ensure accuracy, with optional features like an angle scale and prompting messages to assist users.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gauge head is not maintained parallel to the measurement surface, then the test indicator can be installed at various angles, but the measurement precision deteriorates due to angle errors
Solution Approach 1:
The patent implements a feedback mechanism by detecting the actual installation angle θ of the gauge head relative to the measurement surface and automatically using this angle information to correct the measurement value. The correction unit receives the detected angle and applies the appropriate correction factor, creating a closed-loop system that compensates for angular misalignment errors.
Solution Approach 2:
The patent changes the parameter of the measurement value by applying a correction factor based on the detected installation angle. The correction unit modifies the raw measurement reading by multiplying it with cos(θ) or an appropriate correction coefficient, thereby transforming the inaccurate reading into an accurate measurement value that accounts for the angular deviation.
2Measurement precision
If automatic correction based on installation angle is implemented, then measurement precision is improved, but device complexity increases due to additional sensors and correction mechanisms
Solution Approach 1:
The patent introduces an intermediary correction unit that acts as a bridge between the simple mechanical measurement mechanism and the final accurate reading. This correction unit receives the raw measurement and the detected angle, applies the mathematical correction, and outputs the corrected value, thereby adding minimal complexity while achieving significant precision improvement.
Solution Approach 2:
The patent replaces complex mechanical alignment mechanisms with a simpler electronic/digital solution. Instead of requiring precise mechanical alignment through complex adjustment mechanisms, the system uses angle detection and mathematical correction to achieve the same goal, substituting mechanical complexity with computational simplicity.
3Device complexity
If manual correction of measurement values is required, then device complexity is reduced, but ease of operation deteriorates due to additional correction steps
Solution Approach 1:
The patent implements self-service by enabling the test indicator to automatically perform the correction operation that would otherwise require manual user intervention. The correction unit autonomously detects the installation angle, calculates the appropriate correction factor, and applies it to the measurement value, freeing the user from the burden of manual correction while maintaining measurement accuracy.
4Measurement precision
If the gauge head is kept parallel to the measurement surface, then measurement precision is maintained, but adaptability is reduced as the installation angle must be strictly controlled
Solution Approach 1:
The patent applies dynamics by making the correction factor variable rather than fixed. Instead of requiring a fixed parallel installation, the system dynamically adjusts the measurement value based on the actual installation angle detected during use. This allows the gauge head to be installed at various angles while maintaining measurement precision through real-time correction.
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
Ensures accurate measurement values by simplifying the correction process, reducing user error, and providing corrected measurements directly, thus minimizing the gap between displayed and true values even at large angles.
Implementation Method 1
a rotary encoder configured to detect a rotation displacement amount of the gauge head
Implementation Method 2
the displacement of the contact ball 31 is increased using the principle of lever
Data Source
AI summary
There is provided a test indicator with which a correct measurement value can be easily obtained. A test indicator includes a gauge head including a contact ball at a tip end, a body case which pivotally supports the gauge head, and a rotary encoder which detects a rotation displacement amount of the gauge head. The test indicator further includes a correction unit which corrects a measurement value according to an angle θ between a measurement target surface W and the gauge head. The correction unit includes an angle memory which stores the angle θ between the measurement target surface W and the gauge head, a correction coefficient calculation unit which calculates a correction coefficient according to the angle θ, and a correction arithmetic unit which multiplies, by the correction coefficient, a displacement amount of the contact ball based on a detection value by the rotary encoder.