Cylindrical Mirror Optical System for 360-Degree Bead Measurement
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Solution Overview
Problem
Existing robotic dispensing systems face challenges in measuring the width and height of beads along complex paths without rotating the nozzle, which is difficult to program and requires multiple cameras for 360-degree view, leading to increased costs and fixture size.
Innovation Solution
A measurement system using a cylindrical mirror, two light sources, and two photosensitive arrays positioned to reflect circular arcs onto a substrate, allowing for 360-degree measurement without rotating the camera or light sources, and a processor to detect breaks in the arcs and calculate bead dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If three cameras are used to provide 360 degree view for bead measurement, then measurement capability is improved, but system cost and fixture size increase
Solution Approach 1:
The patent uses a cylindrical mirror to create a virtual copy of the single camera's field of view, reflecting light to provide a 360-degree measurement capability. This virtual copying approach eliminates the need for three physical cameras while maintaining comprehensive bead measurement capability.
Solution Approach 2:
The cylindrical mirror acts as an intermediary element between the single camera and the bead, reflecting light from different angles around the bead path. This intermediary enables a single camera to capture 360-degree views that would otherwise require multiple cameras.
2Manufacturing precision
If nozzle rotation is implemented to maintain consistent bead dispensing direction, then dispensing precision is improved, but programming complexity and robot control difficulty increase
Solution Approach 1:
Instead of rotating the nozzle to maintain consistent dispensing direction, the patent inverts the approach by keeping the nozzle fixed and rotating the measurement system (cylindrical mirror and camera assembly) around the bead path. This allows consistent measurement without complex nozzle rotation programming.
Solution Approach 2:
The patent moves the measurement problem from the nozzle's rotational degree of freedom to the measurement system's rotational degree of freedom. By rotating the cylindrical mirror and camera assembly around the bead path, the system achieves comprehensive measurement without requiring nozzle rotation.
3Device complexity
If single camera is used instead of three cameras, then system cost and size are reduced, but 360 degree measurement capability is lost
Solution Approach 1:
The patent employs a cylindrical mirror with a curved surface that reflects light from all angles around the bead path onto the single camera sensor. This curved geometry enables the single camera to capture 360-degree views by mapping the cylindrical coordinate system onto the camera's planar sensor.
Solution Approach 2:
The measurement system is designed to rotate dynamically around the bead path, allowing the single camera to sweep through 360 degrees and capture bead dimensions from all angles. This dynamic rotation compensates for the single camera's limited static field of view.
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 accurate measurement of bead dimensions without rotating the nozzle or cameras, reducing system size and cost while maintaining a 360-degree view, facilitating efficient robotic dispensing on complex paths.
Implementation Method 1
The light source is configured and positioned with respect to the cylindrical mirror such that light from the light source is reflected from the cylindrical mirror as a circular arc on an object surface
Implementation Method 2
The photosensitive array is positioned with respect to the cylindrical mirror to detect the circular arc on the object surface
Data Source
AI summary
A measurement system includes a cylindrical mirror, a light source, a photosensitive array, and a processor. The light source is configured and positioned with respect to the cylindrical mirror such that light from the light source is reflected from the cylindrical mirror as a circular arc on an object surface. The photosensitive array is positioned with respect to the cylindrical mirror to detect the circular arc on the object surface. The processor is in communication with the photosensitive array and is configured to detect a break in the circular arc and to measure a substance applied to the object surface based on an image detected by the photosensitive array.