3D Laser Calibration System Using Orthogonal Reflective Targets
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Solution Overview
Problem
Current laser projection systems lack a reliable method for three-dimensional calibration, relying on visual estimation which is time-consuming and inefficient, especially in manufacturing applications requiring precise three-dimensional measurements.
Innovation Solution
A three-dimensional enhanced laser projection calibration system comprising a structural frame assembly with a two-dimensional calibration wall and additional three-dimensional structural assemblies, featuring non-movable and movable reflective targets positioned along orthogonal axes, allowing for precise calibration of laser beams and enabling three-dimensional measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual estimation method is used for calibration, then the calibration process is simple to operate, but the calibration time is excessive and efficiency is low
Solution Approach 1:
The patent replaces the manual visual estimation method with an automated optical measurement system. The laser projector projects calibration patterns onto the calibration wall, and cameras capture the patterns to automatically calculate laser beam orientations and offsets, eliminating the need for human visual estimation and significantly reducing calibration time.
Solution Approach 2:
The patent introduces a calibration wall with specific geometric features (cross-member frame, calibration targets) as an intermediary object. This calibration wall serves as a reference standard that enables automated measurement of laser beam positions and orientations, bridging the gap between the laser projector and the measurement system.
2Device complexity
If two-dimensional calibration wall is used, then the calibration process is simplified, but three-dimensional measurement capability is lost
Solution Approach 1:
The patent transitions from a traditional two-dimensional calibration wall to a three-dimensional calibration structure by adding cross-member frames that extend in multiple spatial dimensions. This three-dimensional calibration wall includes vertical members, horizontal members, and depth-wise members that collectively provide reference features for measuring laser beam orientations in three-dimensional space.
3Productivity
If automated calibration system is implemented, then calibration efficiency is improved, but system complexity increases
Solution Approach 1:
The patent designs the calibration wall to serve multiple functions: it provides reference targets for laser beam positioning, structural framework for three-dimensional spatial reference, and mounting surface for calibration targets. This multi-functional design reduces the need for separate calibration components, thereby managing system complexity while maintaining automated calibration capabilities.
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 solution significantly improves the calibration efficiency and accuracy of laser projection systems, enabling them to perform feature-based measurements and enhance manufacturing processes by providing a standardized method for calibrating laser projectors in three-dimensional space.
Implementation Method 1
The non-movable reflective targets and the at least one movable reflective target are each configured to reflect a laser beam from a laser projection system
Data Source
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Figure 4A
AI summary
In an embodiment of the disclosure, there is provided an apparatus for calibrating a laser projection system (120, 228). The apparatus has a structural frame assembly (201, 301) extending along three mutually orthogonal axes (170). The apparatus further has a plurality of non-movable reflective targets (108, 238) disposed on the structural frame assembly (201, 301). The apparatus further has at least three positioning stages (112) coupled to the structural frame assembly (201, 301) respectively about each of the three mutually orthogonal axes (170). At least one movable reflective target (114) is disposed on each positioning stage (112). The non-movable reflective targets (108, 238) and the at least one movable reflective target (114) are each configured to reflect a laser beam from a laser projection system (180, 228).