Laser Pointer Calibration via Visible Light Camera Alignment
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Solution Overview
Problem
Current laser-based thermal temperature sensors require labor-intensive and costly manual alignment of a laser pointer with an infrared spot sensor, which is prone to misalignment due to mechanical shocks or movements, and relies on parallax adjustments that are only accurate at specific distances.
Innovation Solution
A method and system that utilize a visible light camera and infrared array sensor to capture and align images, with a laser pointer, to automatically determine alignment values and store coordinates for calibrating the system, eliminating the need for manual mechanical alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alignment of laser pointer with infrared spot sensor is performed using locking mechanism or epoxy glue, then the relative angle between components is reliably maintained, but the alignment process becomes labor intensive and costly in both time and cost
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated optical alignment system. The visible light camera captures images of alignment targets, and software automatically calculates alignment parameters and adjusts the infrared spot sensor position, eliminating the need for labor-intensive manual alignment while maintaining measurement precision.
Solution Approach 2:
The system performs self-alignment by automatically capturing images, calculating alignment parameters, and adjusting component positions without human intervention. The alignment process is autonomous, with the system using its own imaging and processing capabilities to achieve precise alignment.
2Ease of manufacture
If manual alignment of laser pointer with infrared spot sensor is performed, then alignment can be achieved, but the system becomes prone to misalignment when moved, dropped or mechanically shocked
Solution Approach 1:
The patent replaces fragile mechanical alignment with a software-based dynamic alignment system. Instead of relying on physical locking mechanisms that can fail under shock, the system continuously monitors alignment using the visible light camera and software calculations, automatically compensating for positional changes and maintaining alignment stability.
Solution Approach 2:
The alignment system is made dynamic rather than static. The system continuously captures images and recalculates alignment parameters in real-time, allowing it to adapt to movements and shocks. This dynamic approach replaces static mechanical locking with active software-based adjustment.
3Measurement precision
If parallax adjustments are used to align laser pointer with infrared spot sensor, then alignment accuracy is improved at a given distance, but the alignment becomes distance-specific and not universally accurate
Solution Approach 1:
The patent changes the alignment parameters dynamically based on distance. Instead of fixed parallax adjustments for a specific distance, the system calculates alignment parameters as functions of distance, allowing accurate alignment at any range. The visible light camera captures targets at various distances, and software computes the appropriate alignment corrections for each scenario.
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 simplifies and automates the alignment process, reducing labor and costs, while ensuring accurate positioning of the laser pointer relative to the infrared array sensor, even when the system is moved or subjected to mechanical stress.
Implementation Method 1
a visible light camera (VLC) capable of generating a thermal image, a visible light image
Implementation Method 2
an infrared array sensor (IAS) and a visible light camera (VLC) capable of generating a thermal image
Implementation Method 3
a laser pointer for displaying a laser dot on a target
Data Source
AI summary
A method includes capturing and scaling VLC and an IAS outputs to generate a scaled VLC output and a scaled thermal output (STO), aligning the scaled VLC output to the STO to generate an aligned image based on the scaled VLC output and the STO, determining alignment value(s) based on the aligned image, a laser pointer outputting a light beam to produce a laser dot on a target, and capturing a further output of the VLC. The method includes displaying the further output of the VLC (including a representation of the laser dot (RLD)), and an alignment marker, shifting the alignment marker and/or the RLD to a common position; determining coordinate(s) of the output of the IAS based on coordinate(s) of the further output of the VLC where the alignment marker and the RLD are shown at the common position; and storing the coordinate(s) of the output of the IAS.