Continuous 3D Surface Measurement Using Elastomeric Roller Sensor
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Solution Overview
Problem
Existing tactile sensor systems face challenges in capturing continuous three-dimensional surface data over areas larger than the sensor's contact surface, as they are designed for localized measurements and struggle to adapt to larger surfaces effectively.
Innovation Solution
A tactile sensor system utilizing a matrix of clear elastomer and a reflective surface that scrolls or rolls over the target surface, combined with a camera and light source, captures continuous three-dimensional data by conforming to the object and encoding surface information through light reflection variations, allowing for continuous measurement and imaging of larger surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a traditional tactile sensor is used for localized measurements, then measurement precision is maintained, but the area of measurement is limited to the sensor contact area
Solution Approach 1:
The patent divides the measurement system into two functional parts: a large-area elastomeric matrix that contacts the target surface to capture extensive surface information, and a smaller photosensing structure that detects optical signals. This segmentation allows the system to maintain measurement precision through the photosensor while expanding the measurement area through the flexible elastomer contact surface.
Solution Approach 2:
The patent introduces an intermediary mechanism by using the elastomeric matrix to transfer surface information to the photosensing structure through optical property changes. The elastomer acts as a mediator that deforms in response to surface topography, and this deformation modulates light transmission to the photosensor, enabling precise measurement across a larger area without direct mechanical contact between the sensor and entire surface.
2Area of stationary object
If the sensor contact area is increased to measure larger surfaces, then the area of measurement is improved, but the device complexity increases
Solution Approach 1:
The patent creates an optical copy or representation of the surface topography through the elastomeric matrix deformation. Instead of using a complex array of mechanical sensors across the entire surface, the system uses the elastomer to physically conform to the surface and create a deformable optical interface, which is then read by a simpler photosensing structure. This copying approach reduces device complexity while maintaining large-area measurement capability.
3Productivity
If a static sensor is used for localized measurement, then device complexity is minimized, but the productivity for measuring large surfaces is reduced
Solution Approach 1:
The patent introduces dynamic elements by making the elastomeric contact surface flexible and deformable rather than rigid and static. This allows the sensor to rapidly conform to different surface topographies and capture surface information across a larger area in a single contact, significantly improving measurement productivity. The dynamic elastomer can quickly adapt to various surface geometries without requiring complex mechanical adjustments.
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 efficient and continuous three-dimensional surface measurement of large surfaces, suitable for industrial applications, providing accurate surface gradients and normal maps, and supporting inline inspection and quality control processes.
Implementation Method 1
The reflective skin is illuminated through the elastomer by one or more light sources, and reflects light back toward the photosensing structure
Implementation Method 2
a volume of elastomer capable of transmitting an image
Data Source
AI summary
Continuous measurement of surfaces larger than a sensor is facilitated by the use of a sensor matrix of a clear elastomer and a reflective surface that scrolls, rolls, or otherwise moves over a target surface. A variety of web materials, camera configurations, and handling systems are described to achieve continuous three-dimensional measurement in this context.