Kaleidoscopic Laser Beam Projection With Single-Mirror Scanning
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Solution Overview
Problem
Existing projector devices for diverse laser beam patterns are limited by high cost, mechanical complexity, energy consumption, and size due to the need for multiple moving structures.
Innovation Solution
A kaleidoscopic laser beam projector (KLBP) system utilizing a single rotating mirror deflector with reflective facets and diffractive optical elements to create diverse sweep directions and emission apertures, reducing the number of moving parts to one.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple moving structures are used to emit diverse laser beam patterns, then the projector can achieve diverse sweep directions and emission apertures, but the device complexity, cost, and mechanical reliability deteriorate
Solution Approach 1:
The patent segments the laser beam into multiple independent beams using a diffractive optical element (DOE) that divides a single input beam into multiple output beams. Each beam can then be independently controlled by the rotating mirror, allowing diverse patterns without requiring multiple separate moving structures. This segmentation enables the single mirror to handle multiple beams simultaneously, reducing mechanical complexity while maintaining pattern diversity.
Solution Approach 2:
The single rotating mirror deflector is designed to perform multiple functions: it deflects multiple laser beams simultaneously, creates diverse sweep directions, and works with different emission apertures. By making the mirror universal rather than using separate dedicated components for each function, the system achieves diverse laser beam patterns with reduced mechanical complexity and improved reliability.
2Productivity
If multiple moving structures are used to create diverse laser beam patterns, then scanning capabilities are enhanced, but energy consumption and size increase
Solution Approach 1:
The patent merges the functions of multiple moving structures into a single rotating mirror deflector that handles multiple laser beams simultaneously. Instead of having separate motors and mirrors for each beam, the system combines them into one unified mechanical component, reducing the total energy consumption associated with multiple moving parts while maintaining enhanced scanning capabilities across diverse directions and apertures.
3Adaptability or versatility
If multiple moving structures are used for diverse laser beam projection, then pattern diversity is achieved, but cost and mechanical reliability deteriorate
Solution Approach 1:
The patent extracts the beam division function from the mechanical moving structures by using a diffractive optical element to split the laser beam into multiple independent beams. This separation allows the mechanical system to focus only on direction control through a single mirror, while the pattern diversity is achieved optically through the DOE, thereby improving mechanical reliability by reducing the number of moving components that could fail.
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
The KLBP system achieves a lighter, more compact, energy-efficient, and cost-effective solution with enhanced scanning capabilities, enabling precise inspection and illumination of complex 3D structures with reduced complexity and improved reliability.
Implementation Method 1
A diffractive optical element (DOE) may be employed to divide the beam into multiple diffracted beams
Implementation Method 2
A kaleidoscopic mirror with reflective facets may be employed to redirect the beam(s) in a diversity of directions
Data Source
AI summary
A kaleidoscopic laser beam projector (KLBP) system that employs a single moving structure to project patterns of sweeping laser beams with diverse sweep directions and emission apertures. The system comprises a collimated light source, a spinning mirror deflector (“spindle/flutter mirror”) at the center, and a stationary kaleidoscopic mirror containing multiple facet mirrors arranged in a concave fashion around the spindle mirror. As the spindle mirror rotates, it directs laser beams in a radially whirling movement toward the facet mirrors, which then subdivide these beams into multiple short strokes and redirect them outward in different directions. Various embodiments include configurations with diffractive optical elements (DOEs) for beam splitting, different kaleidoscopic mirror geometries (hexagonal, octagonal, etc.), and innovative flutter mirror mechanisms that create controlled angular variations during rotation. The system enables a “4×1” configuration that replaces traditional “4×4” systems requiring eight motors and multiple moving structures. The KLBP system offers significant advantages including mechanical simplicity, reduced size and weight, improved energy efficiency, enhanced reliability, cost-effectiveness, and modular configurability. The diverse beam incidence angles enable superior illumination of complex three-dimensional objects for applications in machine vision systems, precision metrology, gap and flushness inspection, and robot-assisted assembly of complex structures.