Binocular Laser Measurement with Real-Time Point Cloud Recalibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The binocular laser system faces challenges in maintaining measurement accuracy due to changes in the spatial position of laser instruments caused by machine tool vibrations and variations in external lighting conditions, leading to deviations in the pre-calibrated point cloud coordinate transformation relationship.
Innovation Solution
A method and device for online measurement of a binocular laser system that involves mounting a workpiece and a measuring block, acquiring point cloud data, generating a rigid matching relationship of the measuring block, establishing a coordinate system relationship between the laser instruments, and converting point cloud data to maintain accurate coordinate transformations throughout the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pre-calibration is performed using a standard thickness gauge, then initial measurement accuracy is achieved, but measurement errors occur when spatial position changes due to vibrations or lighting variations
Solution Approach 1:
The patent applies preliminary action by performing pre-calibration of the binocular laser system using a standard thickness gauge before measurement. This establishes an initial coordinate transformation relationship between the left and right laser instruments, preparing the system for accurate measurement while acknowledging that subsequent real-time adjustments are needed to maintain accuracy under varying conditions
Solution Approach 2:
The patent implements feedback by continuously monitoring the coordinate transformation relationship between the two laser instruments during the forming process. When deviations are detected due to vibrations or lighting changes, the system performs real-time re-calibration using point cloud data from both instruments, creating a closed-loop control mechanism that maintains measurement accuracy throughout the process
2Productivity
If coordinate transformation is performed using pre-calibrated relationships, then measurement efficiency is improved, but measurement errors increase when lighting conditions change between calibration and measurement
Solution Approach 1:
The patent applies preliminary action by performing initial calibration to establish coordinate transformation relationships before production measurement, enabling efficient measurement operations. The pre-calibrated transformation matrices allow rapid coordinate system conversions without real-time computation overhead
Solution Approach 2:
The patent implements dynamics by making the coordinate transformation relationship adaptive rather than static. The system dynamically adjusts the transformation parameters based on real-time point cloud data from both laser instruments, allowing the calibration state to evolve and maintain accuracy despite changes in lighting conditions or instrument positions during the forming process
3Measurement precision
If real-time re-calibration is performed during the forming process, then measurement accuracy is maintained, but system complexity and processing time increase
Solution Approach 1:
The patent applies universality by designing the calibration object to serve multiple functions: it provides reference features for initial calibration, enables real-time re-calibration through its geometric characteristics, and acts as a validation standard for measurement accuracy. This multi-functional design reduces the need for separate calibration and measurement systems
Solution Approach 2:
The patent implements copying by using point cloud data from the calibration object to create virtual reference models that are then used for real-time coordinate transformation. Instead of physically re-adjusting the laser instruments, the system creates digital copies of the calibration geometry and uses these for computational re-calibration, reducing mechanical complexity
4Manufacturing precision
If point cloud data from both laser instruments is processed and transformed, then comprehensive workpiece measurement is achieved, but data processing complexity and time increase
Solution Approach 1:
The patent applies preliminary action by performing coordinate system alignment and transformation matrix calculation during the calibration phase before production measurement begins. This pre-computation of transformation relationships eliminates the need for real-time complex calculations during actual workpiece measurement, reducing processing time while maintaining 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 enables real-time calibration of point cloud data transformation relationships, improving measurement accuracy by compensating for spatial position changes and lighting variations, thus enhancing the precision of shape and size measurements of workpieces during industrial processes.
Implementation Method 1
a laser emitted from a first laser instrument and a laser emitted from a second laser instrument of the binocular laser system are projected onto two measuring surfaces of the measuring block
Implementation Method 2
laser emitted from the first laser instrument and a laser emitted from the second laser instrument are projected onto two measuring surfaces
Data Source
AI summary
Disclosed is a method and a device for online measurement of a binocular laser system. The method may include: mounting a workpiece and a measuring block, such that lasers emitted from a first and a second laser instrument are projected onto two measuring surfaces of the measuring block, and projection positions of the lasers emitted from the first and second laser instruments are maintained unchanged; and performing at least one round of cyclic operations until a forming process of the workpiece ends. The cyclic operations may include: acquiring a plurality of pieces of point cloud data, and separating point cloud data to obtain a first, a second, a third, and a fourth point cloud data set; generating a rigid matching relationship; generating a coordinate system relationship; converting the fourth point cloud data set into a fifth point cloud data set; and generating an intermediate shape and size of the workpiece.