Laser Projection Alignment With Photogrammetry for Template Accuracy
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Solution Overview
Problem
Current photogrammetry and laser projection systems are ineffective in achieving precise geometrical accuracy for large-scale object manufacturing in mass production settings, relying on physical templates for dimensional guidance.
Innovation Solution
A laser projection system integrated with a photogrammetry assembly, using industrial cameras and a laser projector to project a template onto a workpiece within a geometric coordinate system, ensuring accurate location and dimensional precision through triangulation and real-time correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical templates are used to direct work on workpieces, then general dimensional accuracy is provided, but manufacturing precision cannot achieve less than one millimeter tolerance
Solution Approach 1:
The patent replaces physical mechanical templates with a laser projection system that projects digital templates onto workpieces. The laser projector displays geometric patterns and dimensional guides optically, eliminating the need for physical steel templates while achieving sub-millimeter manufacturing precision through digital control and photogrammetry-based positioning.
Solution Approach 2:
The patent creates optical copies of template patterns through laser projection onto workpieces. Instead of using physical templates, the system projects digital template images via laser, allowing multiple workpieces to be guided by the same digital template pattern, thereby improving precision while reducing physical template complexity and wear.
2Measurement precision
If photogrammetry is used to locate objects in semiconductor manufacture, then precise location is achieved, but it is not useful for large scale object manufacture in mass production
Solution Approach 1:
The patent adapts photogrammetry technology from its original semiconductor application to universal use across large-scale mass production. The laser projection system integrates photogrammetry cameras and laser projection to create a versatile system that can locate and guide work on various large workpieces (automotive parts, machinery components, etc.), not limited to semiconductors, thereby achieving both precision and broad adaptability.
Solution Approach 2:
The patent scales photogrammetry from microscopic semiconductor measurements to large-scale industrial applications by changing the spatial parameters. The system uses photogrammetry cameras positioned to capture large workpiece geometries, with laser projection scaled accordingly to maintain sub-millimeter precision across meter-scale dimensions, enabling mass production applicability.
3Ease of operation
If laser projectors are used to project assembly templates, then assembly aid is provided, but geometrically accurate projection cannot be achieved in mass production settings
Solution Approach 1:
The patent integrates photogrammetry cameras that capture the actual workpiece geometry and feed this information back to the laser projection system. The system uses this feedback to calculate and adjust the laser template projection in real-time, compensating for workpiece positioning variations and ensuring geometrically accurate projection despite mass production variability, thereby maintaining both ease of operation and high precision.
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 reduces manufacturing tolerance to less than one millimeter, enhancing quality and accuracy while reducing costs by eliminating the need for physical templates.
Implementation Method 1
a laser projector (14) to project a template onto the workpiece (26)... with the assistance of a photogrammetry assembly (12)... determining the position and location of a module which is generating an optical pattern
Implementation Method 2
a laser projector (14) to project a template onto the workpiece (26)... projecting a laser image or template with the assistance of a photogrammetry device provides a manufacturing tolerance of less than one millimeter
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
A laser projection system for projecting an image on a workpiece includes a photogrammetry assembly and a laser projector, each communicating with a computer. The photogrammetry assembly includes a first camera for scanning the workpiece, and the laser projector projects a laser image to arbitrary locations. Light is conveyed from the direction of the workpiece to the photogrammetry assembly. The photogrammetry assembly signals the coordinates light conveyed toward the photogrammetry assembly to the computer with the computer being programmable for determining a geometric location of the laser image. The computer establishes a geometric correlation between the photogrammetry assembly, the laser projector, and the workpiece for realigning the laser image to a corrected geometric location relative to the workpiece.