Compact Laser Scanner Scan Head Design
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Solution Overview
Problem
Conventional laser scanners face challenges in achieving a compact design due to the need for a long light path between the deflection unit and the receiving optics, which increases the overall height and costs, and are prone to core shadowing and optical aberrations.
Innovation Solution
The solution involves moving the receiving optics and routing the transmission path off-axis, allowing both the transmitted and reflected light beams to be deflected by a uniform deflection unit without core shadowing, and using a rotating mirror tilted at 45° to create a compact scan head with a reduced overall height, eliminating the need for costly hollow shaft motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the receiving optics remain stationary while only the deflection unit rotates, then the optical path length must be increased to achieve desired focusing, but this increases the overall height of the scan head
Solution Approach 1:
The patent combines the receiving optics with the rotating deflection unit into a single rotating assembly. This merging eliminates the need for a separate stationary receiving optics position, allowing the light path to be folded within the rotating unit itself, thereby reducing overall height while maintaining focusing precision through the integrated optical design.
Solution Approach 2:
The patent employs beam folding techniques that utilize three-dimensional spatial arrangement within the rotating scan head. By folding the optical path in multiple dimensions rather than using a simple linear arrangement, the design achieves the required light path length for proper focusing without proportionally increasing the overall height of the device.
2Length of stationary object
If beam folding is used to reduce overall height, then the installation space is reduced, but this causes considerable additional costs
Solution Approach 1:
By integrating the receiving optics directly into the rotating deflection unit, the patent eliminates the need for complex beam folding mirrors and additional optical components. This consolidation reduces the number of parts that require precision manufacturing and alignment, thereby lowering manufacturing costs while still achieving compact dimensions.
Solution Approach 2:
The rotating scan head is designed to perform multiple functions: the deflection unit serves both as the scanning element and as the mounting structure for the receiving optics. This multi-functionality reduces the need for separate specialized components, simplifying manufacturing and reducing overall system cost.
3Length of stationary object
If an off-axis parabolic mirror is used instead of a flat rotating mirror, then the proportion between deflection unit and receiving optics is improved in terms of overall height, but core shadowing and optical aberrations occur
Solution Approach 1:
The patent integrates the receiving optics within the rotating scan head assembly, allowing proper optical path length and focusing without requiring the space-saving but problematic off-axis parabolic mirror. This integration maintains reliable optical performance while achieving compact dimensions through clever spatial arrangement rather than exotic optics.
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 design results in a significantly smaller and more cost-effective laser scanner with reduced overall height, improved optical performance, and enhanced reliability, capable of 360° scanning with minimal blind spots.
Implementation Method 1
A light beam generated by a laser periodically scans a surveillance area with the help of a deflection unit. The light is remitted to objects in the surveillance area
Implementation Method 2
A light path with a minimum length is to be provided between the receiving optics and the light receiver in order to achieve the desired focussing of the received light on the light receiver
Implementation Method 3
routing the transmission path off-axis, allowing both the transmitted and reflected light beams to be deflected by a uniform deflection unit... using a rotating mirror tilted at 45° to create a compact scan head
Data Source
Figure 1~2
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Figure 5~6
AI summary
The opto-electric sensor (10) has a light transmitter (12) for emitting a transmitted light beam (16), where the light transmitter is arranged such that the optical axis of the transmitter is parallel to a rotational axis (30) of a movable deflector (18). A light receiver is provided for generating a received signal from a diffusely reflected light beam (22) that is reflected from the objects present in the surveillance area. The transmitted and reflected light beams are deflected at same deflector, where an optical receiver (24) movable with the deflector is mounted on the light receiver. An independent claim is also included for a method for safeguarding surveillance area.