Imaging Device Orientation Control on Compound Curves
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Solution Overview
Problem
Current methods for reproducing images on complex surfaces are time-consuming, lack accuracy, and struggle to properly position and orient imaging devices on irregular surfaces, especially those with compound curves, due to limitations in laser projector control and theodolite functionality.
Innovation Solution
A system that includes an imaging device and a tracker to determine and adjust the orientation of the imaging device relative to the surface, using targets and a tracking instrument to ensure precise positioning and orientation of the image on complex surfaces, allowing for accurate reproduction of images, including lines, crosshairs, and text.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser projector is used to project images onto contoured surfaces, then the imaging process can be performed, but the spatial position and orientation control becomes inaccurate requiring multiple projector heads and additional set-ups
Solution Approach 1:
The patent introduces a tracker as an intermediary device that continuously monitors the position and orientation of the imaging device. This mediator provides real-time feedback data that enables precise control without requiring multiple projector heads or repeated set-ups, thus improving measurement precision while reducing device complexity
Solution Approach 2:
The system implements a feedback mechanism where the tracker continuously monitors the imaging device's spatial parameters and provides real-time data back to the control system. This feedback loop enables dynamic adjustment and maintains accurate position and orientation control throughout the imaging process, resolving the contradiction between precision and complexity
2Ease of operation
If the projection head is placed close to the object to overcome physical obstructions, then the setup becomes simpler, but the focal length is hindered and the entire surface cannot be projected
Solution Approach 1:
The patent employs dynamic positioning where the imaging device can move along the surface being imaged rather than being fixed in a single location. This dynamic approach allows the device to maintain optimal focal distance while progressively covering the entire surface area, overcoming the limitation of physical obstructions without sacrificing coverage
Solution Approach 2:
The imaging process is divided into multiple segments or passes, where the imaging device captures different portions of the surface in sequence. By segmenting the overall imaging task into manageable sections that can be completed from closer distances, the system achieves complete surface coverage while maintaining ease of operation
3Ease of manufacture
If a surface mounted printer is used on irregular surfaces with compound curves, then the equipment setup is simplified, but the firing column is not perpendicular to the surface causing marking position errors
Solution Approach 1:
The tracker provides continuous feedback on the orientation of the imaging device relative to the surface normal. This feedback enables real-time adjustment of the firing column orientation to maintain perpendicularity to the surface, ensuring marking position accuracy even when mounted on irregular surfaces with compound curves
Solution Approach 2:
The patent replaces mechanical alignment methods with an optical tracking system. Instead of relying on physical alignment mechanisms that are difficult to implement on irregular surfaces, the system uses optical tracking to determine and adjust orientation, achieving high precision marking position accuracy while maintaining ease of manufacture
Data Source
AI summary
Systems and methods of reproducing images onto surfaces are disclosed. In one embodiment, the system includes an image file that digitally produces a planar surface normal to a surface of a master model. The planar surfaces are referenced to a coordinate system of the master model through a series of points. A tracker surfacing system, comprising a tracking instrument, generates and emits a signal as the tracking instrument crosses the planar surface. An output device is actuated by the tracking device as it crosses the planar surface, reproducing the series of points as an image onto a surface, including a flat, curved or compound surface. Both the spatial position and orientation of the output device are detected and adjustments are made so that the image is precisely applied to intended locations on the surface being imaged.