Laser Projector Flash Alignment via Photogrammetry
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Solution Overview
Problem
Existing methods for projecting laser templates onto three-dimensional work surfaces are inefficient due to slow target location and calibration, leading to noticeable interruptions in the manufacturing process caused by projection drift and temperature variations.
Innovation Solution
A laser projector assembly that combines a secondary light source with reflective targets and a photogrammetry device to rapidly identify the work surface's three-dimensional location, allowing for precise alignment and reduced alignment time by using the photogrammetry device to signal the processor for accurate target location and laser beam orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser projector methods are used to locate targets and calibrate projection, then manufacturing precision can be maintained, but the process time increases significantly causing noticeable interruptions
Solution Approach 1:
The patent combines the photogrammetry system and laser scanner into a single integrated system that simultaneously performs both functions. The photogrammetry device rapidly locates reflective targets while the laser scanner projects templates, eliminating the need for separate sequential operations and reducing total alignment time while maintaining precision
Solution Approach 2:
The system performs preliminary photogrammetry-based target location before laser scanning begins. By pre-locating targets using the photogrammetry device, the system prepares the coordinate system and target positions in advance, allowing the laser scanner to immediately begin template projection without time-consuming sequential target searching
2Manufacturing precision
If laser template projection is performed on three-dimensional surfaces, then manufacturing tolerances are improved, but the complexity of locating and focusing on the work surface increases
Solution Approach 1:
The patent introduces reflective targets as intermediaries between the laser projector and the three-dimensional work surface. These targets provide easily detectable reference points that simplify the location and calibration process, allowing the system to accurately map the complex three-dimensional surface through relatively simple target-based measurements
Solution Approach 2:
The system replaces complex mechanical alignment procedures with optical-based photogrammetry. Instead of using mechanical measuring devices to locate targets and determine surface geometry, the system uses non-contact optical methods to rapidly capture three-dimensional information and calculate projection parameters
3Manufacturing precision
If periodic target location is performed to check for projection drift, then projection accuracy is maintained, but productivity decreases due to intermittent pattern interruptions
Solution Approach 1:
The patent enables continuous laser template projection by performing target location and drift detection in the background without interrupting the useful action. The integrated system continuously monitors target positions and adjusts projection parameters while the laser pattern remains visible and active, eliminating interruptions that would otherwise stop the manufacturing process
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 method significantly reduces the time required to relocate the work surface during drift or movement, enhancing the precision and quality of laser template projection by eliminating the need for independent target location by the laser scanner.
Implementation Method 1
Light transmitted from the secondary light source toward the work surface is reflected toward the photogrammetry device for determining a location of the work surface
Implementation Method 2
The targets are scanned with a laser beam generated by the laser source for reflecting the laser beam toward a laser sensor
Data Source
AI summary
A method for aligning a laser projector for projecting a laser image onto a work surface is provided. The method includes providing a laser projector assembly with a laser source for projecting a laser image onto a work surface, a secondary light source for illuminating the work surface and a photogrammetry device for generating an image of the work surface. The method also includes affixing reflective targets onto the work surface and transmitting light from the secondary light source toward the work surface and reflecting light toward the photogrammetry device. The method further includes scanning the targets with a laser beam generated by the laser source for reflecting the laser beam toward a laser sensor and calculating a location for projecting the laser image onto the work surface from the reflected laser beam.