Digital Mockup Projection for Workpiece Glare and Surface Distortion
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Solution Overview
Problem
Existing augmented reality projection systems face issues such as dazzling operators due to through cavities and distortion on curved surfaces, which disrupt the usability of projected information.
Innovation Solution
The system adapts projection by detecting the topology and position relative to the projector, adjusting light intensity and modifying the image to compensate for through zones and depth offsets, using real-time image processing and correction algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If projection is performed through cavities in the workpiece, then information can be displayed on the workpiece surface, but the operator is dazzled by the projected light
Solution Approach 1:
The system applies different light intensities to different regions of the projected image based on the local topology of the workpiece. Through zones (cavities) are detected and assigned reduced or zero light intensity, while other regions maintain normal projection intensity. This localized adjustment eliminates operator dazzling in cavity regions while preserving information display quality in safe regions.
Solution Approach 2:
The system performs preliminary detection of the workpiece topology (including through cavities) before projection begins. By pre-identifying hazardous projection paths that would lead to operator dazzling, the system can preemptively adjust the projection pattern to avoid these regions, preventing the harmful effect before it occurs.
2Ease of operation
If projection is performed on curved surfaces with depth offsets, then information can be displayed on the workpiece surface, but distortion occurs in the projected image
Solution Approach 1:
The system performs preliminary scanning and 3D reconstruction of the workpiece surface topology before projection. By pre-calculating the surface geometry (including curved regions and depth offsets), the system can pre-distort the projection pattern in reverse, so that when projected onto the complex surface, the image appears undistorted and geometrically accurate.
Solution Approach 2:
The system dynamically adjusts projection parameters (such as light intensity, projection angle, and image geometry) based on the detected local surface topology. For curved surfaces and depth-offset regions, the projection parameters are modified to compensate for expected distortion, maintaining manufacturing precision across varied surface geometries.
3Manufacturing precision
If the projection system adapts to complex surface topology in real-time, then projection accuracy is maintained, but system complexity increases
Solution Approach 1:
The system creates a digital 3D copy (virtual model) of the workpiece surface topology through scanning and reconstruction. This digital replica is then used for all subsequent projection calculations and adaptations, eliminating the need for complex physical adjustments. The virtual model serves as a precise template for pre-calculating projection patterns, maintaining accuracy while simplifying the physical system.
Solution Approach 2:
The system replaces complex mechanical adjustment mechanisms with computational methods. Instead of physically adjusting projection optics to match surface topology, the system uses software-based 3D reconstruction, topological analysis, and digital image processing to achieve the same effect. This substitution of mechanical complexity with computational algorithms maintains precision while reducing device complexity.
Data Source
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Figure 3
AI summary
Method for projecting onto a real workpiece (4) an image calculated on the basis of a digital mockup (31) recorded on a digital information server (3) associated with said real workpiece, for the viewing of said workpiece under augmented reality, comprising the following steps: capture by a camera of the image of the real workpiece, real-time alignment of the reference frame associated with said digital mockup with the reference frame of the video capture system and the reference frame of the real workpiece, comprising a step of reprocessing of said image calculated as a function of the topology of said digital mockup and as a function of the orientation of the projection means with respect to said real workpiece.