Laser Profiling Attachment for Vision System Camera Setup
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Accurate and efficient setup of laser profiling systems is hindered by the need for precise alignment and calibration of the laser and lens axes, which is time-consuming and prone to variability.
Innovation Solution
A pre-determined profiler assembly with integrated lens and laser components that can be easily mounted onto a vision system camera, allowing for optimized geometry and calibration parameters to be set, including a lens base with a mounting structure and a bar supporting the laser, enabling straightforward adaptation for specific profiling tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate mounting fixtures for laser and lens are used with manual alignment, then flexibility in component selection is improved, but setup time and calibration complexity increase significantly
Solution Approach 1:
The patent combines the laser mounting fixture and lens mounting fixture into a single integrated profiler assembly. The laser and lens are both mounted to the same fixture structure, which is then attached as one unit to the camera. This merging eliminates the need for separate mounting and alignment operations, directly reducing setup time while maintaining the ability to select different laser and lens components for various profiling applications.
Solution Approach 2:
The profiler assembly is pre-configured with the laser and lens mounted in predetermined geometric relationships. The relative positions and angles are established during assembly of the profiler unit itself, before attachment to the camera. This preliminary configuration eliminates the need for time-consuming calibration after mounting, as the geometry is already optimized for the intended profiling task.
2Measurement precision
If manual alignment of laser axis and lens axis is performed, then precise geometric relationships can be achieved, but calibration variability and operator skill dependency increase
Solution Approach 1:
The precise geometric relationship between the laser axis and lens axis is pre-established during the assembly of the profiler unit. The laser and lens are mounted in fixed positions relative to each other on the common fixture, with angles and spacing predetermined for the specific profiling application. This eliminates variability introduced by different operators performing manual alignment, ensuring consistent and repeatable calibration across all units.
Solution Approach 2:
The integrated profiler assembly is self-aligning by design. The fixed geometric relationships within the assembly ensure that when the unit is mounted to the camera, the laser and lens are automatically positioned correctly relative to each other and to the camera sensor. No additional alignment or calibration operations are required, making the system reliable and independent of operator skill level.
3Productivity
If fixed profiler assemblies with predetermined geometry are used, then setup time is reduced, but adaptability to different profiling applications decreases
Solution Approach 1:
The profiler assembly is designed as a universal platform that can be configured for different profiling applications. The common mounting fixture supports various laser types and lens configurations, allowing a single base design to serve multiple purposes. Different profiler units with specific geometric configurations can be developed for different applications, but all share the same mounting interface and basic structure, maintaining high setup efficiency while providing application-specific optimization.
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 simplifies the setup process, reduces time and effort, and ensures accurate and repeatable laser profiling by providing a stable and interchangeable assembly that can be easily adapted for various applications, maintaining precision and accuracy across different profiling tasks.
Implementation Method 1
The profiler uses a particular lens assembly that directs reflected laser light from the planar scene to the sensor at an acute angle with respect to the camera sensor's optical axis (which is perpendicular to the image plane). In this manner, the non-perpendicular angle between the laser axis, lens axis and sensor's image plane can fulfill the so-called Scheimplfug principle so as to define a sharp image of the laser line at every measurement distance
Implementation Method 2
Laser profilers are useful in a wide range of inspection and manufacturing operations where the user desires to measure and characterize surface details of a planar object via triangulation
Data Source
AI summary
This invention provides a system and method for laser profiling that simplifies the task of setting up and using laser profiling systems and associated applications by providing a profiler assembly that includes a predetermined arrangement of lens and spaced-apart laser in which the geometry and calibration parameters are predetermined. The profiler assembly is adapted to mount directly into the camera mount (typically threaded) of a conventional vision system camera. All components needed to perform the profiling task can be integrated into the profiler assembly. The integration of components in a single interchangeable/exchangeable assembly makes it straightforward to optimize/adapt the assembly for a particular profiling application.