Dual-Resolution 3D Scanning for Accurate Large-Surface Stitching
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Solution Overview
Problem
Existing high-resolution scanning devices struggle with errors in relative position alignment when scanning surfaces with large structural separations, especially when lacking intermediate landmarks, leading to significant inaccuracies in combined data sets.
Innovation Solution
A dual-resolution 3D scanner that operates in two configurations, allowing for high-resolution data acquisition at significant structural separations while maintaining precise relative positioning through a combination of low- and high-resolution data sets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high-resolution scanning device is used to scan surfaces with large structural separations, then measurement precision is improved, but device complexity increases and stitching errors occur due to limited viewing area
Solution Approach 1:
The scanning device is divided into two distinct configurations: a first configuration with a first spatial resolution for scanning large areas, and a second configuration with a second spatial resolution for scanning specific structures in detail. This segmentation allows each configuration to be optimized for its specific purpose, resolving the contradiction between high measurement precision and device complexity by providing specialized scanning modes rather than requiring a single complex high-resolution system for all tasks.
Solution Approach 2:
The scanning device dynamically switches between two operational configurations based on the scanning requirements. The system can transition from the first configuration (lower resolution, larger viewing area) to the second configuration (higher resolution, focused viewing area) when encountering structures of interest. This dynamic adaptability resolves the contradiction by allowing the device to use high resolution only when necessary, reducing overall complexity while maintaining measurement precision when needed.
2Measurement precision
If multiple high-resolution data sets are combined to cover large surfaces, then measurement precision is improved, but loss of information increases due to stitching errors
Solution Approach 1:
The scanning process is segmented into two resolution levels: the first configuration captures large-area contextual information with sufficient precision for positioning, while the second configuration captures detailed structural information. By using the first configuration's data for alignment and registration, the system reduces stitching errors when combining multiple data sets, as the lower-resolution contextual data provides a stable reference framework that minimizes accumulation of positioning errors.
Solution Approach 2:
The first configuration's data set acts as an intermediary reference framework that mediates the combination of multiple second configuration data sets. When combining high-resolution data from different scanning positions, the system uses the lower-resolution first configuration data as an intermediate reference to align and register the high-resolution data sets, thereby reducing stitching errors and preserving information integrity across large surface areas.
3Measurement precision
If high-resolution scanning is performed across large areas, then measurement precision is improved, but use of energy increases due to extended scanning time
Solution Approach 1:
The system dynamically adjusts its scanning resolution based on the requirements of the object being scanned. For large surface areas, the first configuration provides sufficient measurement precision at lower energy consumption. When specific structures or features require higher detail, the system transitions to the second configuration only for those localized areas. This dynamic resolution adjustment maintains measurement precision where needed while significantly reducing overall energy consumption compared to scanning the entire large area at high resolution.
Solution Approach 2:
The scanning system applies different quality levels (resolutions) to different regions of the scanned surface. The first configuration provides adequate quality for large-area coverage and contextual positioning, while the second configuration provides high quality only for specific local structures of interest. This local quality differentiation maintains measurement precision for critical features while reducing energy consumption for the overall scanning process by avoiding unnecessary high-resolution scanning of entire large surfaces.
Data Source
AI summary
A 3D scanner system includes a scanning device capable of recording first and second data sets of a surface of an object when operating in a first configuration and a second configuration, respectively. A measurement unit is configured for measuring a distance from the scanning device to the surface. A control controls an operation of the scanning device based on the distance measured by the measurement unit, where the scanning device operates in the first configuration when the measured distance is within a first range of distances from the surface and the scanning device operates in the second configuration when the measured distance is within a second range of distances; and a data processor is configured to combine one or more first data sets and one or more second data sets to create a combined virtual 3D model of the object surface.