Laser Projection Motion Compensation
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Solution Overview
Problem
Existing laser projection systems struggle to accurately project images on dynamic work surfaces due to relative movement between the laser projector and the target, leading to noticeable interruptions and inaccuracies in pattern correction, especially under conditions like vibrations or environmental changes.
Innovation Solution
A method utilizing a high-resolution camera system integrated with the laser projector to continuously track and predict the movement of the laser projector relative to the work surface, allowing for real-time adjustments of the laser beam's position and mirror rotations to maintain pattern accuracy without interrupting the projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sequential scanning of targets is used to calibrate projector position, then measurement precision is improved, but productivity deteriorates due to intermittent corrections and noticeable interruptions in projection
Solution Approach 1:
The patent implements continuous target tracking during projection operation, eliminating the need to stop projection for recalibration. The camera system continuously monitors target positions and updates projector deflection angles in real-time, maintaining uninterrupted projection while achieving continuous position correction.
Solution Approach 2:
The system uses a camera to continuously capture target positions and feeds this information back to the control system, which dynamically adjusts projector deflection angles. This closed-loop feedback mechanism enables real-time correction of projector position drift without interrupting the projection process.
2Device complexity
If intermittent target scanning is used to detect projection drift, then device complexity is reduced, but measurement precision deteriorates due to inability to correct dynamic movement
Solution Approach 1:
The patent replaces the mechanical scanning method with an optical camera-based tracking system. The camera continuously captures target positions optically, enabling high-speed detection of dynamic movements without mechanical moving parts, thus maintaining system simplicity while dramatically improving measurement precision for dynamic conditions.
Solution Approach 2:
The system performs periodic capture of target positions at high frame rates, continuously updating the projector position compensation. This periodic sampling at sufficient frequency enables accurate tracking of dynamic movements while maintaining a relatively simple system architecture.
3Productivity
If high-speed camera tracking is implemented for continuous correction, then productivity is improved through uninterrupted projection, but device complexity increases due to additional camera and processing requirements
Solution Approach 1:
The camera system serves multiple functions: it tracks target positions for projector calibration, monitors dynamic movements during projection, and enables continuous correction of position drift. This multi-functionality justifies the added device complexity by eliminating the need for separate calibration and operation phases.
Solution Approach 2:
The patent combines the calibration and operation phases into a single continuous process by integrating the camera tracking system with the projector control. The same camera and control system used for operation also perform calibration functions, merging previously separate functions into a unified system.
4Device complexity
If traditional sequential target scanning is used, then device complexity is minimized, but reliability deteriorates under dynamic conditions such as vibration or environmental changes
Solution Approach 1:
The system transitions from static, intermittent calibration to dynamic, continuous tracking. The camera system continuously adapts to changing conditions by capturing target positions in real-time and dynamically adjusting projector deflection angles, maintaining high reliability under varying environmental conditions such as vibration or temperature changes.
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 enables precise and continuous correction of the laser image pattern, reducing errors to imperceptible levels, even under dynamic conditions, such as those encountered in aircraft carbon fiber layup, by updating the projection over 10,000 times per second, ensuring high fidelity and accuracy.
Implementation Method 1
at least four targets, typically retro-reflective targets, are fixed relative to the work surface and a laser projector periodically scans the targets
Implementation Method 2
rotating mirrors redirecting the laser beam onto the work surface
Data Source
AI summary
A method of accurately projecting a laser image pattern on a work surface and continuously compensating for relative dynamic movement between the laser and the work surface, including establishing a position of the camera in three dimensions relative to the work surface by locating the targets in the camera image, establishing a position of the laser relative to the work surface utilizing the fixed position of the laser relative to the camera, and using a computer to continuously adjust the rotation of the laser projector mirrors in response to dynamic movement of the laser projector relative to the work surface as determined by the camera. In one embodiment, the computer continuously tracks at least two prior locations of the laser projector relative to the work surface and predicts the next location of the laser, compensating for movement of the laser relative to the work surface.