Dual-optical displacement sensor alignment using knife edges

A method of aligning a dual-optical displacement sensor system including a scanner comprising a first scanner head including a first optical displacement sensor for providing a first beam having a first optical axis (OA) extending substantially in a first direction, and a second scanner head including a second optical displacement sensor for providing a second beam having a second OA extending substantially in the first direction, comprising:

• positioning at least one alignment target providing an integrally-formed first knife edge pair including a first knife edge and a second knife edge offset from the first knife edge in the first direction, the at least one alignment target oriented along a first plane that is essentially perpendicular to the first OA and the second OA and positioned between the first scanner head and the second scanner head for interacting with the first beam and the second beam;
• collecting time versus position data by performing first measurements involving the at least one alignment target in a beam path along the first OA and second measurements involving the at least one alignment target in a second beam path along the second OA;
• from the time versus position data using at least one equation, determining a degree of alignment of the first OA relative to the second OA, and
• adjusting a position of at least one of the first scanner head and the second scanner head so that the first OA and the second OA become more co-linear.

A dual-optical displacement sensor system, comprising:

• a scanner comprising a first scanner head including a first optical displacement sensor for providing a first beam having a first optical axis (OA) extending substantially in a first direction and a second scanner head including a second optical displacement sensor for providing a second beam having a second OA extending substantially in the first direction, and
• a computing device or programmed circuit configured to:
• receive time versus position data from first measurements involving a first alignment target comprising an integrally-formed first knife edge pair including a first knife edge and a second knife edge offset from the first knife edge in the first direction, and a second measurement involving a second alignment target comprising an integrally-formed second knife edge pair including a third knife edge and a fourth knife edge offset from the third knife edge in the first direction wherein the first alignment target is oriented along a first plane that is essentially perpendicular to the first direction and the second alignment target is oriented along a second plane parallel to the first plane;
• analyze using at least one equation the time versus position data for determining a degree of alignment of the first OA relative to the second OA, and
• an algorithm for automatic alignment of the first OA relative to the second OA using the degree of alignment, or provide assist instructions for a user implemented alignment of the first OA and the second OA using the degree of alignment that provides guiding steps for the user for implementing the alignment.