Camera Focus Depth Measurement for Display Manufacturing
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Solution Overview
Problem
Current depth measurement methods in manufacturing processes, such as those for ultra-high definition displays and high pixel density screens, rely on costly and complex sensors like laser distance sensors and confocal sensors, which add substantial complexity and expense.
Innovation Solution
A depth measuring apparatus using a camera and lens assembly with a motion stage and position sensor, employing an image gradient method to determine optimal focus distance and calculate depth levels, eliminating the need for direct contact and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser distance sensors or confocal sensors are used for depth measurements, then measurement precision is improved, but device complexity and cost increase substantially
Solution Approach 1:
The patent replaces complex mechanical depth sensing systems (laser distance sensors, confocal sensors) with a camera-based optical system. The camera captures images at different focus distances, and depth is determined by analyzing the relationship between focus position and image sharpness, eliminating the need for specialized depth sensing hardware.
Solution Approach 2:
The patent uses a camera to capture optical copies (images) of the target at different focus positions. By analyzing the sequence of captured images and their corresponding focus distances, the system reconstructs depth information without requiring direct physical measurement, thus simplifying the overall system.
2Measurement precision
If laser distance sensors or confocal sensors are used for depth measurements, then measurement precision is improved, but manufacturing cost increases substantially
Solution Approach 1:
The patent employs a camera, which is a relatively inexpensive and widely available component compared to specialized depth sensors. The system uses standard imaging technology that can be manufactured at lower cost and integrated into existing manufacturing processes without requiring expensive proprietary sensors.
Solution Approach 2:
The patent substitutes expensive specialized sensing hardware with a camera-based system that uses standard optical components and image processing algorithms, significantly reducing the bill of materials cost while maintaining measurement capability.
3Device complexity
If camera focus distance method is used for depth measurements, then device complexity is reduced, but measurement precision may be compromised
Solution Approach 1:
The patent performs preliminary focusing adjustments by capturing a sequence of images at different focus distances before final depth determination. This preliminary action of sampling multiple focus positions allows the system to establish the focus-distance relationship that will be used for accurate depth measurement, improving precision without requiring complex real-time processing.
Solution Approach 2:
The patent uses image sharpness analysis as feedback to determine the optimal focus distance for each depth level. By analyzing the clarity and focus of captured images, the system automatically adjusts and identifies the correct focus-position-to-depth correspondence, ensuring measurement accuracy through iterative optimization.
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 provides accurate and cost-effective depth measurements without the complexity of traditional sensors, improving manufacturing efficiency and reducing costs by using camera focus distance to determine depth levels.
Implementation Method 1
a camera and lens assembly capable of capturing image data for a sequence of images of a target containing a plurality of depth levels along a camera axis
Implementation Method 2
a position sensor capable of capturing relative position data of the camera and lens assembly or the target along the camera axis at each incremental value of movement
Data Source
AI summary
A depth measuring apparatus includes a camera assembly configured to capture a plurality of images of a target at a plurality of distances from the target. The depth measuring apparatus further includes a controller configured to, for each of a plurality of regions within the plurality of images: determine corresponding gradient values within the plurality of images; determine a corresponding maximum gradient value from the corresponding gradient values; and determine, based on the corresponding maximum gradient value, a depth measurement for a region of the plurality of regions.