AR Headset Overlay for 3D Component Assembly
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Solution Overview
Problem
Conventional manufacturing methods for complex workpieces face challenges with accuracy when using mechanical fixtures or optical templates, as they struggle with three-dimensional coordinate systems and cannot accurately project components with geometrically important features floating above the workpiece surface.
Innovation Solution
A method combining a laser projector with an imaging device and display to generate a virtual image of a component in a geometrically accurate location on a workpiece, using a headset for augmented reality to overlay a computer-generated image onto a live video stream, allowing accurate assembly and verification of components with three-dimensional characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser projector projects a template onto a workpiece surface, then the template provides accurate two-dimensional placement guidance, but it cannot provide three-dimensional characteristics of components floating above the surface
Solution Approach 1:
The patent introduces an imaging device (camera) as an intermediary to capture the workpiece and projected template, then uses a display device to overlay a virtual three-dimensional component model onto the captured image. This intermediary system bridges the gap between the two-dimensional laser projection and the need for three-dimensional component information, allowing operators to see both placement guidance and component characteristics simultaneously.
Solution Approach 2:
The patent transitions from two-dimensional laser template projection to three-dimensional virtual reality visualization by capturing the workpiece image with a camera and overlaying three-dimensional CAD models of components in their correct spatial positions. This adds the vertical dimension and three-dimensional spatial relationships that were missing from traditional laser projection, enabling accurate placement guidance while preserving complete component geometric information.
2Manufacturing precision
If mechanical fixtures are used to register to a workpiece at a fixed location, then assembly accuracy can be maintained, but the fixtures become difficult to work with when large or heavy
Solution Approach 1:
The patent replaces the mechanical fixture system with an optical-digital system consisting of a laser projector, imaging device, and display device. Instead of physically positioning heavy mechanical fixtures on the workpiece, the system uses laser projection and virtual reality overlay to provide alignment guidance, eliminating the need for operators to manually position and secure large mechanical fixtures while maintaining assembly accuracy.
3Manufacturing precision
If manual measurement of attachment locations is performed using reference features or templates, then component placement can be achieved, but the process becomes expensive and labor intensive with high error propensity
Solution Approach 1:
The patent implements a self-service system where the laser projector automatically projects the template onto the workpiece, the imaging device automatically captures the workpiece and template alignment, and the display device automatically generates and displays the virtual component overlay. This eliminates the need for manual measurement and interpretation by operators, reducing labor intensity and human error while maintaining high precision attachment location accuracy.
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 enhances assembly accuracy by providing a three-dimensional image of components in precise location and orientation, overcoming limitations of traditional laser projection systems and enabling accurate placement of components with complex geometries.
Implementation Method 1
A laser projector projects a plurality of laser images relative to the workpiece
Implementation Method 2
An imaging device captures images of the workpiece and the laser images
Data Source
AI summary
A method of identifying an accurate assembly of a component onto a workpiece to an operator includes the use of a laser projector and a headset or goggles. The laser projector projects laser images relative to the workpiece. The headset or goggles includes an imaging device and a display element. A location of the laser projector, the imaging device and the display element is registered in a common coordinate system relative to the workpiece. The imaging device generates an image of a view of the workpiece appearing in the display element when viewed by the operator though the display element. A computer generated image of the component is overlaid upon the image of the workpiece being disposed in a geometrically accurate location on the image of the workpiece. The image of the workpiece appearing in the display element is registered to the three dimensional coordinate system defined relative to the workpiece.