Test Indicator With Replaceable Stylus And Encoder Correction
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Solution Overview
Problem
Conventional test indicators have limited measurement range due to the fixed length of their stylus, which restricts their ability to accurately measure deep inner surfaces and requires multiple models for different measurement conditions, leading to increased costs and storage needs.
Innovation Solution
A test indicator with a replaceable stylus of varying lengths, equipped with an encoder and a calculation unit that corrects measurement values based on stylus length, rotation angle, and flexure errors, allowing for a wider measurement range and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the stylus length is increased to measure deeper inner surfaces, then the reaching range is improved, but flexure occurs in the stylus causing large measurement errors
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the stylus length parameter through replacement with styli of different lengths (e.g., 10mm, 15mm, 20mm) depending on measurement requirements. The control unit receives stylus length information and uses it to calculate appropriate correction values, transforming the fixed-parameter system into a variable-parameter system that adapts to different measurement scenarios.
2Measurement precision
If the stylus length is fixed to maintain measurement accuracy, then measurement precision is improved, but the measurement range is limited and multiple models are required
Solution Approach 1:
The patent implements universality by designing a single test indicator body that can accommodate multiple styli of different lengths. The control unit is configured to receive information about the attached stylus length and automatically adjust correction calculations accordingly. This allows one device to perform multiple measurement functions across different depth ranges, eliminating the need for separate models for different measurement scenarios.
Solution Approach 2:
The system transitions from a static, fixed stylus configuration to a dynamic system where the stylus length can be changed based on measurement requirements. The control unit dynamically adjusts correction values based on the detected stylus length and rotation angle, enabling the same hardware to adapt to varying measurement conditions without requiring multiple dedicated devices.
3Length of moving object
If the rotation angle is increased to expand measurement range, then the reaching range is improved, but the difference between arc length and vertical displacement increases causing measurement errors
Solution Approach 1:
The patent employs feedback mechanisms where the encoder detects the actual rotation angle of the stylus, and this information is fed back to the control unit. The control unit uses the detected rotation angle to calculate arc-chord error correction values, which are then applied to compensate for the increasing difference between arc length and vertical displacement. This closed-loop feedback system maintains measurement accuracy even at larger rotation angles.
Solution Approach 2:
The patent replaces pure mechanical measurement with a hybrid system combining mechanical detection and computational correction. Instead of relying solely on mechanical leverage principles that assume small angles, the system uses an encoder to detect rotation angle and a control unit to computationally correct for arc-chord errors, substituting mechanical accuracy assumptions with electronic sensing and digital calculation.
4Adaptability or versatility
If multiple models with different stylus lengths are prepared to change stylus length, then adaptability is improved, but device complexity and storage needs increase
Solution Approach 1:
The patent realizes universality by designing a single test indicator model that can function with multiple stylus lengths. The body case is designed to accommodate different stylus sizes, and the control unit is programmed to recognize and adapt to the attached stylus length. This eliminates the need for maintaining separate inventory of different models while providing the same adaptability benefits.
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
Enables accurate measurement of deeper inner surfaces and expanded measurement ranges, reducing the need for multiple tools and lowering procurement and storage costs while maintaining high accuracy and resolution.
Implementation Method 1
an encoder configured to detect a rotation displacement amount of the stylus
Implementation Method 2
a flexure calculation unit configured to correct the reference flexure error δsf according to the length of the stylus to calculate an actual flexure error δcf being an actual flexure error
Data Source
AI summary
There is provided a test indicator 100 capable of replacing a stylus 210 with another stylus 210 having a different length to increase a reaching range of the stylus 210, and of increasing a rotation angle of the stylus 210 to display an accurate measurement value in a wide measurement range.A calculation unit 400 of the test indicator 100 includes a stylus-length storage unit 420 that sets and stores a length of the stylus 210, and a stylus-length correction calculation unit 400 that changes, according to the length of the stylus 210, a conversion ratio for converting a detection value by an encoder 340 into a measurement value to correct the measurement value. The calculation unit 400 further includes a rotation-angle calculation unit 410 that calculates a rotation angle αs[rad] of the stylus 210 based on the detection value by the encoder 340 and an arc-chord error correction calculation unit 400 that multiplies a sine value using the rotation angle αs calculated by the rotation-angle calculation unit 410 as an argument to correct the measurement value.