3D Object Inspection via 2D Height Displacement Map
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Solution Overview
Problem
Current methods for measuring three-dimensional features of manufactured objects are inefficient and prone to errors due to the need for precise target location and the use of complex algorithms, resulting in slow measurement speeds and limited data points.
Innovation Solution
A method and apparatus using a line of radiation projected onto an object, detecting the reflected radiation, generating a two-dimensional height displacement map, and processing the intensity of spots using two-dimensional image processing techniques to measure object features and dimensions, eliminating the need for precise target positioning and complex three-dimensional algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If spot laser systems are used to measure three-dimensional features, then measurement can be performed at specific points, but the number of measurable points is limited and measurement speed is slow due to sequential point-by-point scanning
Solution Approach 1:
The patent transitions from one-dimensional point-by-point scanning to two-dimensional area scanning by projecting a laser line across the entire target surface simultaneously. The line laser projects a line of radiation that illuminates multiple points across the target at once, and the sensor captures the reflected light from all these points simultaneously, creating a two-dimensional height displacement map. This dimensional change from sequential point measurement to parallel area measurement dramatically increases the number of measurable points and measurement speed while maintaining precision through pixel-level intensity analysis.
2Quantity of substance
If line laser systems are used to scan targets, then more points can be measured simultaneously, but complex three-dimensional algorithms are required for processing which increases computation time
Solution Approach 1:
The patent extracts and eliminates the complex three-dimensional algorithms from the processing pipeline. Instead of using traditional 3D reconstruction algorithms that require intensive computation, the system uses a simplified two-dimensional image processing approach. The intensity of reflected light at each pixel location directly correlates with height information, allowing the system to process the data using efficient 2D image processing techniques while still obtaining accurate three-dimensional feature measurements.
3Measurement precision
If spot or line laser systems are used, then height differences can be measured, but precise target location is required before inspection which adds positioning complexity
Solution Approach 1:
The system employs self-service through automatic target acquisition and positioning. The line laser automatically illuminates the entire target area, and the sensor automatically captures the reflected light pattern. The system self-adjusts and adapts to the target's position and orientation without requiring precise pre-positioning. The two-dimensional height displacement map is generated automatically from the captured image data, eliminating the need for manual or complex automated positioning systems.
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
This approach allows for fast and accurate measurement of three-dimensional features without requiring precise target location, using two-dimensional image processing to quickly and efficiently calculate object heights and dimensions, improving measurement speed and reducing errors.
Implementation Method 1
detecting at least one line of radiation reflected from the object
Data Source
AI summary
The present disclosure provides a system and method to convert three-dimensional data into a two-dimensional height displacement map and extract the three-dimensional features and dimensions of a three-dimensional object using a two-dimensional image processing technique. An illumination source of the system scans across the workspace using a line laser and generates a two-dimensional height displacement map of the workspace. The individual pixel location represents an actual workspace sampled location. The pixel gray scale intensity represents the Z displacement height at the pixel location. A processing device processes the features and dimensions within two-dimensional image as a gray scale using two-dimensional image processing such as pattern match, blob, convolution and edge detection.