Multi-Camera Frame Alignment Inspection Using Lasers and Mirrors
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Solution Overview
Problem
Existing methods struggle to accurately inspect the alignment of multiple cameras in a multi-camera display system before assembly, leading to potential misalignments that affect the 3D rendering quality in telepresence systems, and existing metrology equipment is inadequate for measuring small position and orientation differences between mounting features on large frame assemblies.
Innovation Solution
A testing system and method that uses mirrors and lasers to determine camera alignment by reflecting laser beams onto a backboard with targets, allowing for visual feedback on alignment accuracy without requiring camera installation or additional circuitry, facilitating rapid inspection of frame assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing metrology equipment is used to measure camera alignment, then measurement capability is limited, but measurement precision is insufficient for small position and orientation differences on large frame assemblies
Solution Approach 1:
The patent introduces mirrors as intermediary objects attached to camera mounts, which reflect laser beams to create measurable optical paths. This intermediary mechanism enables precise measurement of small alignment differences by converting positional deviations into measurable laser reflection displacements, avoiding the need for complex direct measurement equipment.
Solution Approach 2:
The system creates an optical copy of the camera mount alignment through laser reflection off mirrors. Instead of directly measuring the physical camera positions, the system projects laser beams that reflect off mirrors mounted on the camera brackets, creating an optical representation of the alignment state that can be precisely measured and compared against target positions.
2Manufacturing precision
If camera alignment inspection is performed before assembly, then alignment accuracy is improved, but inspection time and fabrication time increase
Solution Approach 1:
The patent performs camera alignment inspection before cameras are permanently installed in the frame assembly. By attaching mirrors to the camera mounts and conducting laser-based alignment verification at this preliminary stage, the system ensures accurate camera positioning is established early in the fabrication process, preventing rework and enabling faster subsequent assembly operations.
Solution Approach 2:
The system provides visual feedback through a backboard displaying target positions and actual laser reflection positions. This immediate feedback mechanism allows operators to quickly assess alignment accuracy and make real-time adjustments to mirror or camera mount positions, streamlining the alignment process and reducing iteration time during fabrication.
3Productivity
If multiple cameras are inspected simultaneously, then productivity is improved, but measurement complexity increases
Solution Approach 1:
The patent divides the multi-camera inspection system into independent, identical measurement channels, each consisting of a laser source, mirrors attached to individual camera mounts, and corresponding target positions on the backboard. This segmentation allows each camera alignment to be measured independently and simultaneously without interference, simplifying the overall system architecture while enabling parallel inspection of multiple cameras.
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
Ensures precise camera alignment within tolerance, improving the 3D rendering quality of telepresence systems without added cost or complexity, and enabling high-volume production by shortening fabrication times.
Implementation Method 1
activating a laser to radiate a laser beam to the mirror, the mirror generating a reflection of the laser beam
Data Source
AI summary
A multi-camera display for a telepresence system may include a plurality of cameras aligned around a display panel large enough to display a person at scale. Aligning the cameras to particular directions can allow for images captured by the cameras to be combined to render a 3D image. The quality of the rendering may decrease when any or all of the cameras are misaligned. The present disclosure describes a system and method to test a frame assembly for a multi-camera display that uses mirrors and lasers to sense the camera alignments and targets to visually inspect the quality of the sensed camera alignments. Testing using this approach may simplify the testing because the alignments may be visually tested simultaneously, and the testing may be performed before the cameras are installed.