Laser Scanner Calibration Using Reference Plate and Camera
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Solution Overview
Problem
Existing calibration techniques for laser scanning systems in additive manufacturing are expensive, complex, and require limited-use parts or complex sensor systems, necessitating a need for fast, accurate, and automated calibration methods.
Innovation Solution
A calibration system using a motion-controlled camera and a reference calibration plate with predefined markings, where the camera captures images of laser markings on the plate to determine precise coordinates, allowing for scanner corrections and calibration without expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive, limited-use calibration parts or complex sensor systems are used, then calibration accuracy is improved, but cost and device complexity increase
Solution Approach 1:
The patent uses a digital image copy of the calibration plate captured by a standard camera instead of requiring expensive specialized sensors. The calibration markings are captured as an image and processed computationally to extract coordinate information, replacing complex optical sensors with a simple camera and image processing algorithm
Solution Approach 2:
The patent replaces complex mechanical calibration systems with a combination of a simple camera and computer vision algorithms. Instead of using specialized mechanical measurement devices or complex sensor arrays, the system uses digital image processing to achieve precise calibration measurements
2Measurement precision
If traditional calibration methods are used, then calibration accuracy is maintained, but calibration time and operational complexity increase
Solution Approach 1:
The calibration plate is pre-marked with a known pattern of markings at specific coordinates before the calibration process begins. This preliminary preparation allows the system to directly compare captured images against the known reference pattern, enabling rapid automated calibration without time-consuming manual measurements or iterative adjustments
Solution Approach 2:
The system uses the calibration plate's own pre-existing markings as the reference standard, eliminating the need for external calibration equipment or operators. The calibration process is self-contained, using the plate's inherent geometric features to automatically determine scanner accuracy and generate correction data
3Measurement precision
If specialized calibration equipment is used, then measurement accuracy is improved, but ease of manufacture and accessibility worsen
Solution Approach 1:
The calibration plate is designed with a universal marking pattern that can be manufactured using standard fabrication processes and used with any laser scanner. The pattern consists of geometric markings that can be created with ordinary tools, making the calibration system manufacturable and accessible without requiring specialized equipment or proprietary components
Data Source
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AI summary
A system and method for calibrating a laser scanning system is provided. Various embodiments involve the use of a calibration plate with reference markings which is positioned to receive a directed beam in a set of known laser scanner positions. The directed beam forms a laser spot on the calibration plate, and the laser spot is captured using an image acquisition assembly such as a digital camera along with a motorized mount. The movement of the image acquisition assembly may be coordinated with the movement of the laser scanner to track the laser spot across the plate. After photographing various positions, actual laser spot coordinates are deduced from their position relative to the known positions of the reference markings.