3D Laser Projection for Non-Cylindrical Utility Poles
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Solution Overview
Problem
Existing laser projection systems face challenges in accurately positioning virtual templates on multi-faced communication or utility poles, as they require reflective fiducial markers and struggle with projecting onto non-cylindrical structures with corners and twists, leading to errors in placement of components like step clips.
Innovation Solution
A method using a laser pointer to trace points along corners of the pole, feeding this information into a 3D Laser Projection System to determine attachment locations, allowing for the registration of CAD drawings and generation of virtual templates without physical markers, enabling accurate placement of components on multi-faced poles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If reflective fiducial markers are used for laser projection positioning, then positioning accuracy is improved, but the complexity of the process and additional materials required worsen
Solution Approach 1:
The patent removes the fiducial markers from the positioning process entirely. Instead of adding markers to the pole surface for the laser projector to detect, the system uses direct edge detection and corner point identification on the bare pole surface, eliminating the need for additional positioning materials and simplifying the overall process
Solution Approach 2:
The pole structure itself serves as the reference for positioning. The laser projector detects corners and edges that naturally exist on the pole, using the pole's own geometry as the fiducial reference rather than requiring external markers. This self-referencing approach eliminates the need for separate fiducial elements
2Ease of operation
If physical templates are used for component placement, then ease of operation is improved, but manufacturing precision and adaptability to complex pole structures worsen
Solution Approach 1:
The patent replaces physical templates with a virtual template system projected by laser. Instead of using mechanical physical templates that must be manually positioned and aligned, the system projects laser lines and virtual outlines directly onto the pole surface, allowing for precise digital positioning and easier adjustment without physical handling
Solution Approach 2:
The patent transitions from 2D physical templates to 3D virtual laser projections. The laser projector creates three-dimensional virtual templates in space that can be precisely positioned and adjusted, allowing operators to view and work with component placement guides from multiple angles and perspectives
3Productivity
If existing laser projection systems are used on multi-faced poles, then productivity is maintained, but manufacturing precision and reliability of component placement worsen due to errors on non-cylindrical structures
Solution Approach 1:
The patent implements a dynamic positioning system that adapts to the specific geometry of each pole. Rather than using fixed projection patterns, the system dynamically identifies corner points and edges in real-time, calculates appropriate positioning parameters, and adjusts the virtual template projection accordingly to accommodate varying pole shapes and orientations
Solution Approach 2:
The system changes key geometric parameters based on detected pole features. By identifying corner points and measuring distances between them, the system dynamically adjusts projection parameters such as laser line orientation, virtual template positioning, and scaling factors to ensure accurate component placement on multi-faced pole structures
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 the placement process by eliminating the need for physical measurements and fiducial markers, ensuring precise alignment and spacing of components on complex pole structures, enhancing manufacturing efficiency and quality.
Implementation Method 1
a laser projector can be used to project 3D laser outlines derived from a CAD file onto a 3D object, e.g., the pole
Data Source
AI summary
Techniques that can overcome challenges for providing a virtual template for placing a part onto a utility or communication pole that includes twists that extend along at least a portion of a length of the pole. A user to use a laser pointer to trace along a corner between faces of a non-cylindrical pole, and feed that location registration information to the laser projection system to use in determining the location at which to place the virtual template on the utility or communication pole.