Triangulation Sensor Thermal Stability Design
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Solution Overview
Problem
Optical sensors face challenges in maintaining accuracy due to environmental temperature fluctuations, leading to thermal sensitivity issues that current technologies have not adequately addressed.
Innovation Solution
A sensor device structure with a metal housing and optical frame design that minimizes opto-mechanical thermal sensitivity, featuring a lens barrel with protrusions for direct lens contact and a secure fastening system, along with a method of curing adhesive at elevated temperatures to enhance thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical sensor structures are used, then manufacturing is simpler, but thermal sensitivity is higher and accuracy deteriorates under temperature fluctuations
Solution Approach 1:
The patent applies thermal expansion principles by designing the optical frame and lens barrel with specific geometric relationships that compensate for thermal expansion effects. The optical frame is configured with a first elongate slot and the lens barrel with a second elongate slot, where the relative expansion and contraction of these components under temperature changes maintains stable optical alignment and reduces thermal sensitivity, thereby improving measurement precision across temperature variations.
2Stability of the object's composition
If metal components are used throughout, then thermal stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the optical assembly into distinct metal components including an optical frame, lens barrel, and housing, each with specific functions. The optical frame provides structural support and thermal stability, the lens barrel houses the optical elements, and the housing protects the assembly. This segmentation allows each component to be optimized for its specific function while maintaining overall thermal stability without requiring the entire structure to be complex.
Solution Approach 2:
The patent employs composite material strategies by combining metal components (optical frame, lens barrel, housing) with adhesive materials to create a multi-material structure. The metal components provide thermal stability and mechanical strength, while the adhesive materials provide bonding and environmental sealing. This composite approach achieves thermal stability without requiring all components to be metal, thereby reducing manufacturing complexity.
3Ease of manufacture
If adhesive is used to secure components, then assembly is easier, but thermal sensitivity increases due to adhesive expansion
Solution Approach 1:
The patent applies parameter changes by curing the adhesive at an elevated temperature (e.g., 100°C or higher) to alter its physical and chemical properties. This high-temperature curing process changes the adhesive's expansion characteristics, reducing its coefficient of thermal expansion and minimizing its contribution to thermal sensitivity. The cured adhesive then provides stable bonding across temperature variations, maintaining optical alignment precision while preserving assembly ease.
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 solution achieves a relative reduction in thermal sensitivity, allowing the sensor to operate accurately across a wide temperature range (−25° C to 90° C) with improved precision and stability.
Implementation Method 1
curing the adhesive at an elevated temperature to minimize thermal expansion and reduce opto-mechanical thermal sensitivity
Data Source
AI summary
A sensor device has a metal sensor housing with a housing base coupled to a frame base of a metal optical frame. A device mounting plate is orthogonal to the frame base. A securing device secures an optical communication device to the device mounting plate. A barrel mounting channel has first and second sidewalls, each extending obliquely to the frame base and defining a linear translation pathway along the frame base for a metal lens barrel. A fastener secures the metal lens barrel to the first and second sidewalls. A glass lens is in contact with three protrusions extending outward from an inner annular surface of the lens barrel. The optical communication device is configured to be in optical communication with the lens and is secured in a particular position in a translation plane mutually defined by the device mounting plate and the optical communication device.