Handheld 3D Scanner Using Ethernet Power and Data Transfer

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Solution Overview

Problem

Handheld line scanners face challenges such as lengthy data processing delays, reduced resolution leading to loss of fine features, range limitations due to electrical cable lengths, and excessive noise from speckle, necessitating improvements in data processing and power transmission.

Innovation Solution

A system comprising a handheld unit with a light source, image sensor, and Ethernet cable, coupled with an accessory device for data extraction and power transmission, enabling direct determination of 3D coordinates and eliminating the need for adhesive markers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If data processing is performed by an external computer, then data processing capability is sufficient, but data processing delays occur

Engineering Contradiction:

Improvedata processing speedVSAvoiddata processing delay

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system divides processing tasks between the handheld scanner (image capture and initial processing) and the external computer (final coordinate determination). This segmentation allows parallel processing, reducing overall delay while maintaining sufficient processing capability at each stage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The handheld scanner performs preliminary image capture and data extraction before transmitting to the external computer. This preliminary action reduces the amount of data needing external processing, thereby reducing total processing delay while maintaining accuracy.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If resolution is reduced to speed processing, then data processing speed increases, but fine features are lost

Engineering Contradiction:

Improvedata processing speedVSAvoidfine feature detection

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system processes only the necessary portions of image data at high resolution (areas containing fine features) while using lower resolution for other areas. This partial action approach maintains fine feature detection capability while improving overall processing speed.

Inventive Principle:

Principle #16Partial or excessive action

3Length of moving object

If electrical cable length is increased to extend range, then operating range increases, but cable constraints remain

Engineering Contradiction:

Improveoperating rangeVSAvoidcable constraint

Core Design Contradiction:

Length of moving objectVSEase of operation

Solution Approach 1:

The system replaces the mechanical electrical cable connection with wireless communication technology. This substitution eliminates cable constraints entirely while extending the operating range, allowing the handheld scanner to operate freely without physical connection limitations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If adhesive markers are used for coordinate registration, then registration accuracy is achieved, but additional processing steps are required

Engineering Contradiction:

Improvecoordinate registration accuracyVSAvoidprocessing steps

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system uses self-service features of the object itself (natural geometric features, surfaces, and structures) for coordinate registration instead of requiring external adhesive markers. This eliminates the need for additional marker application and removal steps, reducing processing complexity while maintaining registration accuracy through the handheld scanner's intrinsic measurement capabilities.

Inventive Principle:

Principle #25Self-service

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

Facilitates faster and more accurate 3D coordinate determination with reduced speckle noise, allowing for seamless data processing and power transmission without cable constraints.

Implementation Method 1

an image sensor operable to capture an image of light reflected from the object

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

send electrical power over the Ethernet cable to the handheld unit

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12483625B2Handheld scanner that transfers data and power over ethernet

Publication Date: 2025.11.25 FARO TECHNOLOGIES INC

AI summary

A system includes a handheld unit having a light source, an image sensor, one or more first processors, an Ethernet cable, and a frame. The light source projects light onto an object, and the image sensor captures an image of light reflected from the object. One or more first processors are directly coupled to the frame. An accessory device has one or more second processors that receive data extracted from the captured image over the Ethernet cable and, in response, determine three-dimensional (3D) coordinates of points on the object. The accessory device also send electrical power over the Ethernet cable to the handheld unit.