Dual-Camera Digital Projector for Micron Measurement Context
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Solution Overview
Problem
Existing optical profile grinders struggle with highly accurate measurement in microns while maintaining a wide field of view, as increasing magnification narrows the imaging range and makes it difficult to identify the observed portion of the workpiece or grinding wheel.
Innovation Solution
A digital projector system with a low-magnification camera mechanism for a wide view and a high-magnification camera mechanism for pinpoint observation, using a beam splitter to capture and display both images simultaneously, allowing for accurate measurement and observation of both large and small details.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the magnification of the camera is increased to perform measurement in microns, then the measurement precision is improved, but the field of view becomes extremely narrow
Solution Approach 1:
The imaging system is segmented into two independent camera mechanisms: a low-magnification camera for wide field of view and a high-magnification camera for precise measurement. Each camera operates independently at its optimal magnification level, allowing simultaneous acquisition of both wide-area context and detailed measurement data without the trade-off present in single-camera systems.
2Measurement precision
If the magnification of the camera is increased, then the measurement precision is improved, but it becomes difficult to identify which portion of the workpiece or grinding wheel is being observed
Solution Approach 1:
The imaging results from both the low-magnification camera and high-magnification camera are merged into a single composite display. The low-magnification image provides the overall context showing the entire workpiece or grinding wheel, while the high-magnification image is superimposed or positioned to show the specific measurement area, allowing operators to simultaneously understand both the global context and local details.
3Measurement precision
If the magnification of the camera is increased, then the measurement precision is improved, but the observation portion is easily lost when the workpiece or grinding wheel is moved slightly
Solution Approach 1:
The system implements feedback through real-time image processing and display control. When the workpiece or grinding wheel moves, the low-magnification camera continuously monitors the overall position, and the system automatically adjusts the high-magnification camera's imaging position or updates the composite display to maintain the observation portion within the visible range, preventing loss of the measurement area.
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 highly accurate measurement with a wide field of view by combining low- and high-magnification images, ensuring precise identification of workpiece and grinding wheel details.
Implementation Method 1
a beam splitter provided on a light path of the projected image
Implementation Method 2
a high-magnification image-forming lens that enlarges the projected image to a predetermined magnification
Data Source
AI summary
A digital projector according to one aspect includes: a light source that irradiates an object to be machined with light; a low-magnification camera mechanism that captures a projected image of the object to be machined, generated by the irradiation by the light source; a beam splitter provided on a light path of the projected image; a high-magnification camera mechanism that captures the projected image, split by the beam splitter, in a range narrower than the low-magnification camera mechanism and at a magnification higher than the low-magnification camera mechanism; and a display that displays a low-magnification image captured by the low-magnification camera mechanism and a high-magnification image captured by the high-magnification camera mechanism. The high-magnification camera mechanism includes a high-magnification image-forming lens that enlarges the projected image to a predetermined magnification, a high-magnification camera that captures the projected image enlarged, and a high-magnification camera movement mechanism that changes an imaging position of the high-magnification camera with respect to the projected image.