Laser Scanner Reference Sheet Extraction for Measurement Accuracy
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Solution Overview
Problem
Conventional laser scanners using rigid-flexible PCBs with attached reference sheets face increased assembly complexity, manufacturing costs, and reduced accuracy due to deformation and ambient light noise interference, which complicates accurate distance measurement.
Innovation Solution
A laser scanner design featuring a housing with a window, a motor-driven mirror, a light source, a PCB with an opening for the laser beam, a reference sheet spaced from the PCB to diffuse and reflect the laser beam, and light-transmissive and light-receiving lenses to guide and concentrate the beam, effectively separating noise reflection and improving the light reference configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid-flexible PCB with attached reference sheet is used, then the light reference path can be constituted, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The reference sheet is extracted from the rigid-flexible PCB structure and positioned independently within the housing. This allows the reference sheet to be separately installed and adjusted without requiring complex rigid-flexible PCB assembly, thereby reducing assembly complexity while maintaining the light reference function
Solution Approach 2:
The light reference path is segmented into separate components: the reference sheet is separated from the PCB structure and positioned independently. This segmentation allows each component to be optimized and assembled separately, reducing overall assembly complexity
2Reliability
If a rigid-flexible PCB with attached reference sheet is used, then the light reference path can be constituted, but the manufacturing cost increases
Solution Approach 1:
The reference sheet is extracted from the expensive rigid-flexible PCB structure and implemented as a simple independent component within the housing. This substitution with a simpler, cheaper component reduces manufacturing cost while preserving the light reference measurement function
Solution Approach 2:
The reference sheet is implemented as a simple, inexpensive component rather than requiring expensive rigid-flexible PCB material. This use of a cheaper alternative achieves the same functional purpose at lower manufacturing cost
3Reliability
If the reference sheet is attached to the flexible PCB, then the light reference path is formed, but the shape deformation occurs due to assembly tolerance
Solution Approach 1:
The reference sheet is extracted from the flexible PCB structure and positioned independently with a fixed mounting position in the housing. This independent positioning eliminates the shape deformation caused by flexible PCB bending and assembly tolerance accumulation, ensuring stable geometric relationships
Solution Approach 2:
The reference sheet is separated from the flexible PCB and mounted independently at a fixed position. This segmentation breaks the chain of tolerance accumulation and prevents shape deformation, as each component can be manufactured and assembled independently with its own tolerance budget
4Volume of moving object
If the reference sheet is close to the PCB, then the structure is compact, but the ambient light noise reflection interferes with measurement accuracy
Solution Approach 1:
The encoder PCB serves as an intermediary element that blocks ambient light noise from reaching the light receiver. By positioning the reference sheet behind the encoder PCB relative to the light receiver, the encoder PCB mediates to prevent noise interference while allowing the compact arrangement to be maintained
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 design simplifies assembly, reduces costs, and enhances measurement accuracy by separating noise reflections and optimizing the light reference path, leading to improved distance measurement precision.
Implementation Method 1
a reference sheet which is erected inside the window and erected at a point that is spaced apart from the PCB in a horizontal direction to diffuse and reflect the laser beam passing through the opening
Implementation Method 2
a reference sheet which is erected inside the window and erected at a point that is spaced apart from the PCB in a horizontal direction to diffuse and reflect the laser beam passing through the opening
Implementation Method 3
a light-transmissive lens disposed between the light source and the mirror to guide the laser beam emitted from the light source to the mirror
Implementation Method 4
a light-receiving lens configured to concentrate the laser beam, which is diffused and reflected from the reference sheet to pass through the opening, into the light-receiving element
Data Source
AI summary
A laser scanner according to an embodiment of the present invention comprises: a housing; a window coupled to the upper surface of the housing; a motor mounted on the inner upper end of the window; a mirror slantly connected to the rotary shaft of the motor so as to reflect light; a light source arranged under the mirror so as to emit a laser beam toward the mirror; a PCB which is erected in the lateral direction of the mirror and which has an opening through which the laser beam reflected from the mirror passes; a reference sheet which is erected inside the window, and which is erected at a point separated from the PCB in the horizontal direction so as to spread and reflect the laser beam having passed through the opening; a light-transmissive lens arranged between the light source and the mirror so as to standardize, as parallel light, the laser beam emitted from the light source; a light-receiving element for receiving the laser beam, which is diffusely reflected from the reference sheet so as to pass through the opening; and a light-receiving lens for concentrating, at the light-receiving element, the laser beam, which is diffusely reflected from the reference sheet so as to pass through the opening.