Laser Videogrammetry for Real-Time Surface Measurement
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Solution Overview
Problem
Traditional photogrammetry and laser projector techniques for measuring large surfaces, such as aircraft components, are too slow, hindering the manufacturing process by prolonging production timelines.
Innovation Solution
A system combining a laser projector device and a videogrammetry device to simultaneously measure surface angles and geometry, using a laser projector to direct beams and a videogrammetry device to capture video images, allowing for real-time 3D coordinate calculations and comparison with digital blueprints to ensure accurate contour formation during fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional photogrammetry or laser projector techniques are used to measure large surfaces, then measurement capability is provided, but measurement speed is too slow
Solution Approach 1:
The patent combines a laser projector device and a videogrammetry device into a unified measurement system. The laser projector projects laser beams onto the surface while the videogrammetry device captures images of the reflected beams, merging two separate measurement capabilities into a single coordinated system that achieves faster measurement speeds.
Solution Approach 2:
The system enables continuous measurement by simultaneously projecting laser beams and capturing images throughout the fabrication process. The videogrammetry device continuously records the laser beam positions on the surface, allowing real-time measurement without interrupting the manufacturing workflow.
2Manufacturing precision
If traditional measurement techniques are used, then surface geometry can be measured, but the overall manufacturing process is prolonged
Solution Approach 1:
The measurement system provides real-time feedback to the fabrication process by continuously monitoring surface geometry and comparing it against desired contours. The controller processes measurements from both devices and can immediately identify deviations, allowing for real-time adjustments to maintain manufacturing precision without delaying production.
Solution Approach 2:
The system performs measurements at intermediate steps of the fabrication process rather than only at the end. By measuring the surface after initial or intermediate fabrication steps, the system enables early detection and correction of deviations, preventing time-consuming rework later in the process.
3Loss of time
If a single measurement device is used, then device complexity is reduced, but measurement time increases
Solution Approach 1:
The patent merges a laser projector device and a videogrammetry device into a coordinated measurement system. While this increases device complexity, the synergistic operation of both devices enables simultaneous measurement capabilities that significantly reduce total measurement time compared to using a single device sequentially.
Solution Approach 2:
The combined system performs multiple measurement functions simultaneously - the laser projector provides angle measurements and the videogrammetry device provides position measurements - which would otherwise require separate measurement operations. This multi-functionality reduces the total time needed to complete the measurement 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 approach significantly reduces measurement time, enabling real-time feedback and accelerating the fabrication process while ensuring precise surface contour formation, thus meeting production timelines efficiently.
Implementation Method 1
A laser projector device and a videogrammetry device simultaneously measure the surface of an object... the laser projector device includes a laser element mounted on a two-axis gimbal assembly. The laser projector device is configured to control the two-axis gimbal assembly to direct laser beams from the laser element onto target points on a surface of the object
Implementation Method 2
the videogrammetry device is able to capture a video image of the laser beams reflecting off of the surface
Implementation Method 3
Another way to measure the shape of an object's surface is with a laser projector. A laser projector uses a laser device to reflect laser beams off of different points along a surface of an object, and measures the angles for each of the points
Data Source
AI summary
Systems and methods for measuring a surface of an object. The system, in one embodiment, includes a laser projector device mounted at a fixed location relative to an object being formed by a fabrication process, and a videogrammetry device mounted at another fixed location relative to the object. The laser projector device includes a laser element mounted on a two-axis gimbal assembly, and the gimbal assembly directs laser beams from the laser element onto target points on a surface of the object. The laser projector device measures angles of the laser beams to the target points, while the videogrammetry device simultaneously performs measurements of the target points by capturing video images of the laser beams reflecting off of the target points. A controller processes the measurements from the laser projector device and the videogrammetry device to calculate x, y, z coordinates of the target points in a 3D coordinate system.