Dual-Magnification Digital Projector for Micron Measurement Context
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical profile grinders struggle with highly accurate measurement in microns while maintaining a wide field of view, as increasing camera 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 both low- and high-magnification camera mechanisms, allowing simultaneous observation of a wide field of view using a low-magnification image and pinpoint observation at higher magnification, using a high-magnification image, with a beam splitter to split and transmit or reflect projected images for both cameras.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera magnification is increased to perform measurement in microns, then measurement precision is improved, but field of view becomes extremely narrow
Solution Approach 1:
The imaging system is segmented into multiple camera mechanisms with different magnifications (low-magnification camera mechanism and high-magnification camera mechanism). Each camera is responsible for capturing images at its optimal magnification level, allowing the system to simultaneously provide both wide field of view and high measurement precision by selecting or combining images from different segments.
2Measurement precision
If camera magnification is increased to perform measurement in microns, then 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 system implements a nested display structure where the high-magnification image (pinpoint observation) is superimposed on or positioned relative to the low-magnification image (wide field of view). This nesting allows the operator to see both the detailed measurement area and its context within the overall workpiece, preventing loss of contextual information while maintaining high measurement precision.
3Measurement precision
If camera magnification is increased to perform measurement in microns, then measurement precision is improved, but the observation portion is easily lost when workpiece or grinding wheel is moved slightly
Solution Approach 1:
The system provides continuous feedback by displaying both low-magnification and high-magnification images simultaneously or alternately. When the workpiece or grinding wheel is moved, the low-magnification image provides immediate feedback about the new position, allowing the operator to quickly reorient and maintain the observation portion within the field of view, thus improving observation stability.
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 and measurement of workpiece and grinding wheel details.
Implementation Method 1
a beam splitter 36 provided on a light path of the projected image
Data Source
Figure 1
Figure 2
Figure 3~4
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.