Laser Projector Calibration for Drape-Molding

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Solution Overview

Problem

Manual calibration of laser projectors in drape-molding operations is time-consuming and requires frequent recalibration when molds are repositioned, especially in large parts manufacturing, leading to extended operation durations and ergonomic challenges for operators.

Innovation Solution

A device and method featuring a support system with a fixed and movable element, calibration patterns, and encoders that enable automatic calibration of laser projectors by detecting and measuring displacement, allowing for ergonomic repositioning and reducing manual recalibration steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual calibration of laser projector is performed, then positioning accuracy is achieved, but manufacturing time is significantly extended

Engineering Contradiction:

Improvepositioning accuracyVSAvoidmanufacturing time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The calibration patterns are attached to the mold in advance before the drape-molding operation begins. This preliminary placement of reference markers enables the laser projector to perform automatic calibration by detecting these pre-positioned patterns, eliminating the need for time-consuming manual calibration procedures while maintaining positioning accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual mechanical calibration process is replaced by an automated optical detection system. The laser projector uses its detection system to automatically recognize the calibration patterns on the mold and compute the transformation parameters, substituting the manual mechanical adjustment process with an automated vision-based calibration approach that is both faster and more precise.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If mold is repositioned for large part manufacturing, then ergonomic working conditions are improved, but recalibration time increases operation duration

Engineering Contradiction:

Improveergonomic working conditionsVSAvoidoperation duration

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The recalibration process after mold repositioning is automated through the detection system that recognizes calibration patterns. This replaces the manual mechanical recalibration process, allowing the mold to be repositioned multiple times for ergonomic reasons without incurring significant time penalties, as the system automatically adapts to new positions through pattern detection and transformation computation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The calibration patterns serve multiple functions: they are attached once to the mold and can be used for initial calibration as well as for recalibration after any number of repositionings. This universal reference system enables the mold to be moved freely for ergonomic reasons while maintaining calibration capability, supporting both ergonomic operation and time efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If frequent mold repositioning is performed, then operator ergonomics are enhanced, but device complexity increases due to recalibration requirements

Engineering Contradiction:

Improveoperator ergonomicsVSAvoidrecalibration system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The complex manual recalibration procedure is replaced by an automated detection and computation system. The laser projector's detection system automatically identifies calibration patterns and the computer calculates transformation parameters, eliminating the need for operators to perform complex manual recalibration steps. This automation reduces the perceived device complexity for the operator while enabling frequent repositioning for ergonomic reasons.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-calibration by automatically detecting the calibration patterns and computing the necessary transformation parameters without human intervention. This self-service capability allows the mold to be repositioned freely for ergonomic reasons, as the system autonomously handles the recalibration process, thereby enhancing operator ergonomics without adding operational complexity.

Inventive Principle:

Principle #25Self-service

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

Significantly reduces manufacturing time by automating the calibration process, enhancing ergonomics and efficiency in drape-molding operations, particularly in the aeronautical field, by eliminating the need for manual recalibration after mold repositioning.

Implementation Method 1

at least one laser projector arranged to draw, on the mold, contours delimiting areas for depositing the plies

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

the projector comprising a detection system arranged to detect the calibration patterns

Methodology Applied

Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS11400666B2Laser projection device and method for manufacturing composite material parts by drape-molding

Publication Date: 2022.08.02 SAFRAN NACELLES

AI summary

A laser projection method and device for drape-molding a part on a mold includes encoders to determine the theoretical position of calibration patterns according to a displacement of the mold such that a laser projector is automatically recalibrated when the mold is repositioned during the drape-molding operation.