Curved Specular Panel 3D Surface Mapping With Reflected Patterns
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Solution Overview
Problem
Manufacturers of sheets or panels with specular surfaces struggle to quickly and accurately measure the shape and optical distortion of curved panels during transportation or assembly, as existing methods are inefficient and lack precise three-dimensional surface information acquisition.
Innovation Solution
A system utilizing a conveyor, displays projecting contrasting patterns, and uniquely paired cameras to capture reflected images, combined with geometric and differential geometry equations to develop a three-dimensional mathematical description of the panel surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple cameras and displays are used to cover the entire panel surface, then measurement coverage is improved, but device complexity increases
Solution Approach 1:
The panel surface is divided into multiple measurement zones, each covered by a dedicated camera-display pair. This segmentation allows comprehensive coverage of the entire panel while maintaining manageable complexity for each individual measurement unit.
Solution Approach 2:
The system transitions from single-point or line measurement to two-dimensional surface measurement by arranging multiple cameras and displays in a spatial configuration that covers the entire panel area, adding dimensional coverage capability.
2Productivity
If the panel is measured while being conveyed, then productivity is improved, but measurement precision may deteriorate due to motion
Solution Approach 1:
The system is configured in advance with cameras and displays positioned at specific locations along the conveyor path. The measurement zones are pre-defined and each camera-display pair is calibrated for its specific zone, allowing accurate measurement to be taken at multiple points along the conveyance path without requiring the panel to stop.
Solution Approach 2:
The measurement process continues uninterrupted as the panel moves along the conveyor. Multiple cameras capture surface data at different positions simultaneously, ensuring continuous measurement coverage throughout the conveyance process without stopping the production flow.
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
Enables rapid and accurate acquisition of three-dimensional surface information, allowing for analysis of optical distortion and comparison with predefined surfaces, integrated into manufacturing processes for improved quality control.
Implementation Method 1
the camera detects the reflected image of the pattern projected on the surface of the panel from its associated display
Data Source
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AI summary
A system for acquiring surface data from one of the surfaces of a curved panel having a specular surface and developing a surface definition of the panel includes a conveyor for conveying the panel in a first direction, at least one display projecting a preselected multi-phase non-repeating contrasting pattern, and at least one camera, each one of the cameras uniquely paired with one of the displays. The system may also include a control programmed to execute logic for controlling each of the camera/display pairs to acquire the desired images, and logic for analyzing and combining the data acquired by the cameras to construct a definition of the surface of the panel.