Adjustable Laser Line Module Using Shifted Micro-Lens Arrays
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Solution Overview
Problem
Existing laser line triangulation devices require manual recalibration and measurement interruptions to adjust the measurement range for objects of different sizes, limiting their suitability for automated use and increasing total measuring time.
Innovation Solution
A laser line module with a line adjusting unit comprising two micro-lens arrays and an actuator allows for varying the length of the laser line without changing the working distance, using an Alvarez configuration to change the total refractive power by shifting the micro-lens arrays relative to each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual exchange of projector and camera objectives is performed to adjust measurement range, then measurement adaptability to different object sizes is improved, but measurement time increases and automation suitability deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the laser line length adjustable through relative movement of micro-lens arrays. Instead of manually exchanging objectives, the system dynamically changes the measurement range by shifting micro-lens arrays along the optical axis, enabling continuous adjustment of laser line length from a few millimeters to several meters without interrupting the measurement process.
Solution Approach 2:
The patent implements parameter changes by varying the refractive power of the laser line module through controlled displacement of micro-lens arrays. By changing the position parameters of the micro-lens arrays relative to each other, the system adjusts the divergence angle and length of the projected laser line, allowing adaptation to different object sizes without physical component exchange.
2Measurement precision
If manual recalibration of cameras is performed when changing objectives, then measurement accuracy is maintained, but productivity decreases due to measurement interruptions
Solution Approach 1:
The patent ensures continuity of useful action by enabling seamless adjustment of measurement range without interrupting the measurement workflow. The micro-lens arrays can be repositioned during operation to adapt to different object sizes, eliminating the need to stop for recalibration and maintaining continuous productive measurement.
Solution Approach 2:
The system implements self-service through automated control of micro-lens array positions. The relative arrangement of micro-lens arrays is controllable via actuation mechanisms that automatically adjust the laser line length according to measurement requirements, eliminating manual intervention and recalibration operations.
3Reliability
If fixed measurement distance is maintained for different objects, then optical focus is optimized, but adaptability to objects of varying sizes is limited
Solution Approach 1:
The patent applies local quality by creating different laser line lengths from a single optical system. The micro-lens arrays locally modify the light propagation characteristics to produce varied line lengths (from millimeters to meters) while maintaining the same working distance, allowing optimization for specific measurement regions without changing the overall optical configuration.
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 and efficient measurement of objects of varying sizes within a defined range with reduced data capture and direct visual feedback, enhancing measurement precision and automation suitability.
Implementation Method 1
The Alvarez lens comprises a first micro-lens array (15) and a second micro-lens array (16)... By shifting the micro-lens arrays relative to one another, the total refractive power can be changed
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5b
AI summary
The invention pertains to a laser line module LLM (1) for projecting a laser line onto a surface of a distant target object. The laser line module (1) comprises a light emitting assembly (10a) configured to emit measuring radiation, the light emitting assembly comprising a laser diode (11) and a beam shaping assembly, wherein the laser diode (11) and the beam shaping assembly are arranged and configured to guide the measuring radiation along an optical axis (OA) of the laser line module (1). The LLM comprises a line adjusting unit (10b) successively arranged to be irradiated by the measuring radiation of the light emitting assembly (10a) and configured to manipulate the measuring radiation to provide the laser line with a defined laser line length, the line adjusting unit comprising a first micro-lens array (15) having a first beam-manipulation surface having a multitude of first microlenses which define a first periodic height profile and providing a first refractive power. The line adjusting unit (10b) comprises a second micro-lens array (16) comprising a second beam-manipulation surface having a multitude of second microlenses which define a second periodic height profile and providing a second refractive power, and an actuator coupled to the second micro-lens array (16) and providing movability of the second micro-lens array (16) relative to the first micro-lens array (15).