Workpiece Holder Alignment Using Optical Misalignment Correction
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Solution Overview
Problem
Existing workpiece inspection apparatuses face challenges in achieving high-accuracy inspections due to misalignment between the symmetry axis of the workpiece and the rotary axis of the motor, leading to difficulties in capturing precise images.
Innovation Solution
A workpiece holder with a chuck mechanism that can detect and correct misalignment by moving orthogonal to the rotary axis, ensuring the symmetry axis aligns with the rotary axis during rotation, utilizing a horizontal positioning mechanism and a rotary mechanism to adjust the chuck mechanism's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the workpiece is held and rotated by a simple holder unit, then the device complexity is reduced, but the alignment precision between the symmetry axis and rotary axis deteriorates
Solution Approach 1:
The holder unit is divided into functionally independent modules: a chuck mechanism for holding the workpiece, a positioning mechanism for adjusting radial position, and a rotary mechanism for rotation. This segmentation allows each module to be optimized independently, maintaining low overall complexity while achieving high alignment precision through coordinated operation of the modules.
Solution Approach 2:
The patent replaces complex mechanical alignment mechanisms with an optical measurement system. An alignment imaging part captures images of the workpiece outer peripheral portion, and a misalignment detector uses image processing to detect symmetry axis position, substituting mechanical alignment adjustment with optical-field measurement and computational detection.
2Manufacturing precision
If misalignment detection and correction mechanisms are added, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The system performs self-alignment through automated detection and correction. The alignment imaging part automatically captures images, the misalignment detector automatically processes images to detect symmetry axis deviation, and the positioning mechanism automatically adjusts the workpiece position. This self-service capability eliminates the need for manual alignment operations and complex mechanical adjustment mechanisms.
Solution Approach 2:
The system implements a closed-loop feedback control mechanism where the alignment imaging part continuously monitors the workpiece position, the misalignment detector processes the visual information and determines correction requirements, and the positioning mechanism executes corrections based on detected misalignment. This feedback loop maintains high alignment precision without requiring overly complex mechanical structures.
3Productivity
If the workpiece is rotated at high speed for inspection, then the productivity is improved, but the measurement precision of misalignment deteriorates
Solution Approach 1:
The system performs misalignment detection and correction in advance, before the high-speed inspection rotation begins. The alignment imaging part captures images during initial positioning, the misalignment detector analyzes the images to determine symmetry axis deviation, and the positioning mechanism corrects the position before inspection starts. This preliminary alignment ensures that subsequent high-speed rotation occurs with accurate alignment, maintaining both measurement precision and productivity.
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
This solution enables high-accuracy alignment and inspection of workpieces by correcting misalignment, allowing for precise image capture and improved inspection accuracy.
Implementation Method 1
an alignment imaging part that captures an image of the outer peripheral portion of the workpiece held by the chuck mechanism
Data Source
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AI summary
In order to match a symmetry axis of a workpiece and a rotary axis with each other with high accuracy, a workpiece holder comprises: a holding table including: a chuck mechanism that holds the workpiece; a positioning mechanism that moves the chuck mechanism in a direction orthogonal to the rotary axis while supporting the chuck mechanism to locate the workpiece; and a rotary mechanism that rotates the positioning mechanism about the rotary axis to rotate the workpiece held by the chuck mechanism about the rotary axis by; an alignment imaging part that captures an image of the outer peripheral portion of the workpiece held by the chuck mechanism; a misalignment detector that detects misalignment of the symmetry axis with respect to the rotary axis on the basis of the image captured by the alignment imaging part while the workpiece is rotated by the rotary mechanism; and a workpiece position correction part that corrects the position of the workpiece in such a manner as to match the symmetry axis with the rotary axis by moving the chuck mechanism using the positioning mechanism so as to eliminate the misalignment.