Cellular Core Surface Profiling Using Structured Light
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Solution Overview
Problem
Conventional surface profiling technologies, such as photogrammetry and structured light projection systems, struggle to accurately measure the 'virtual' surface formed by the ends of the machined walls of cellular cores in lightweight structures, due to their limited spatial resolution and accuracy.
Innovation Solution
A cellular core profiling system utilizing a digital image projector and two digital cameras to capture images with uniform and structured light, transforming 2D representations into a 3D surface map by identifying cell walls, optimizing junction locations, and calculating labels for each cell, employing epipolar geometry and bundle adjustment techniques for improved estimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional photogrammetry or structured light projection systems are used, then measurement coverage area is improved, but measurement precision and spatial resolution deteriorate when measuring cellular core virtual surfaces
Solution Approach 1:
The patent segments the cellular core surface into individual cell units, each treated as a separate measurement target. By identifying and measuring each cell's characteristics (position, orientation, dimensions) individually, the system achieves high spatial resolution across the entire large area surface, resolving the contradiction between coverage area and measurement precision
Solution Approach 2:
The patent introduces structured light patterns as an intermediary to enhance the measurability of the featureless cellular core surface. The projected light patterns create visible features on each cell that can be detected and measured, enabling precise spatial resolution while maintaining large area coverage
2Device complexity
If traditional photogrammetry with sparse targets is used, then device complexity is reduced, but measurement precision deteriorates on featureless surfaces
Solution Approach 1:
The system uses the cellular core's own geometric structure (cell walls, corners, and patterns) as measurement features, eliminating the need for external targets. The structured light projection serves the dual purpose of illumination and feature creation, allowing the system to achieve high measurement precision while maintaining simplicity by leveraging the workpiece's inherent characteristics
3Measurement precision
If high spatial sampling density is achieved, then measurement accuracy is improved, but processing time increases
Solution Approach 1:
By segmenting the surface into discrete cells and developing efficient algorithms to identify and measure each cell's characteristics, the system can process high-density spatial data more efficiently. The cell-based approach allows for optimized computation compared to continuous surface processing, reducing processing time while maintaining high measurement accuracy
Solution Approach 2:
The patent implements a two-stage processing approach where initial measurements are taken at lower resolution, followed by selective refinement of critical areas. This partial action strategy achieves high measurement accuracy where needed while reducing overall processing time by avoiding exhaustive high-resolution processing of the entire large area surface
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
The system achieves high-resolution measurement of the virtual surface defined by the ends of the cellular core walls, enabling precise surface profiling of complex structures with tens of thousands of cells, reducing processing load through optimized parameter application.
Implementation Method 1
A digital image projector, two digital cameras, and a processor in which two, 2-dimensional representations of the 3-dimensional surface are transformed into a 3-dimensional representation of the original surface
Implementation Method 2
two digital cameras, and a processor in which two, 2-dimensional representations of the 3-dimensional surface are transformed
Implementation Method 3
in which two, 2-dimensional representations of the 3-dimensional surface are transformed into a 3-dimensional representation of the original surface
Data Source
AI summary
Embodiments of the present invention determine the surface profile of certain classes of work surface. More specifically, embodiments of the invention measure the three-dimensional locus of points that define the “virtual” continuous surface fitted to the ends of the walls of a cellular core.