3D Surface Measurement via Electronic Light Pattern Projection
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Solution Overview
Problem
Current 3D surface measurement technologies, such as mechanical scanning and laser triangulation, are inefficient and costly due to the need for precise mechanical motion and struggle with accuracy on surfaces with low color contrast or identifying features, while stereo-vision methods face challenges with pixel matching and data noise.
Innovation Solution
A system comprising a pattern projector, digital imaging devices, and an image processing device that projects and moves a light pattern electronically across a surface, converting the pattern into three-dimensional data points without mechanical motion, using relative positions and angles to achieve accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical scanning technology with point or line distance sensor is used, then measurement precision can be achieved, but device complexity and cost increase due to precise conveyance mechanism requirements
Solution Approach 1:
The patent replaces the mechanical scanning system with an optical projection system. Instead of moving a distance sensor mechanically, the system projects a light pattern onto the surface and uses digital imaging to capture the deformed pattern, eliminating the need for precise mechanical conveyance mechanisms while maintaining measurement capability.
Solution Approach 2:
The patent creates an optical copy of the surface geometry by projecting a light pattern and capturing its deformation through digital imaging. The measured data represents a copy of the surface three-dimensional structure, allowing measurement without physical contact or mechanical scanning.
2Measurement precision
If mechanical scanning is used to achieve acceptable precision, then measurement accuracy improves, but productivity decreases due to slow data gathering speed
Solution Approach 1:
The patent transitions from one-dimensional point scanning to two-dimensional pattern projection. By projecting a light pattern that covers the entire measurement area simultaneously and capturing it with a digital imaging device, the system measures all points in parallel rather than sequentially, dramatically increasing data gathering speed while maintaining precision.
Solution Approach 2:
The patent enables continuous measurement by projecting light patterns and capturing images without mechanical movement. The electronic control allows rapid sequential projection of different patterns and capture of images, maintaining continuous useful action without the interruptions and speed limitations of mechanical scanning.
3Ease of operation
If laser triangulation with point type sensor is used, then measurement can be performed, but measurement precision decreases due to lower resolution and higher data noise
Solution Approach 1:
The patent upgrades from point-type measurement to area-type measurement by projecting light patterns that illuminate entire regions of the surface. The digital imaging device captures deformation information across the entire pattern, providing two-dimensional resolution information that significantly improves measurement precision over single-point laser triangulation.
4Area of stationary object
If stereo-vision method is used for complete measurement, then measurement coverage improves, but measurement precision decreases due to difficulty in pixel level feature matching
Solution Approach 1:
The patent uses light patterns with different intensities or colors projected onto the surface to create artificial features that are easily distinguishable by the digital imaging device. This eliminates the difficulty of matching natural surface features, allowing precise pixel-level correspondence identification even on surfaces with low color contrast or lacking identifying features.
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 approach enables fast, accurate, and energy-efficient 3D surface feature measurement, particularly suitable for pavement texture and other features, providing comprehensive and stable results without the limitations of existing methods.
Implementation Method 1
The pattern projector projects a pattern of light on a surface of an object
Implementation Method 2
at least one of the digital imaging devices records, during use, at least one image of the projected patter of light
Data Source
AI summary
In some embodiments, a system for measuring surface features may include a patter projector, at least one digital imaging device, and an image processing device. The pattern projector may project, during use, a pattern of light on a surface of an object. In some embodiments, the pattern projector moves, during use, the pattern of light along the surface of the object. In some embodiments, the pattern projector moves the pattern of light in response to electronic control signals. At least one of the digital imaging devices may record, during use, at least one image of the projected patter of light. The image processing device which, during use, converts projected patterns of light recorded on at least one of the images to three-dimensional data points representing a surface geometry of the object using relative positions and relative angles between the at least one imaging device and the pattern projector.