Light Pattern Projection for Precise Work-Piece Cutting
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Solution Overview
Problem
Operators using handheld cutting tools face challenges in accurately replicating intricate details on work-pieces due to visual limitations, leading to inaccurate cuts and reduced quality of the resulting structure.
Innovation Solution
A system comprising a projection device and optical sensor that captures light signals from the work-piece surface, estimates surface features, and projects a pattern of light based on these features to assist operators in performing precise cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If operators use handheld cutting tools with reference designs, then cutting operations can be performed, but intricate details on the work-piece surface become visually unnoticeable leading to inaccurate cuts
Solution Approach 1:
The system projects a pattern of light onto the work-piece surface that highlights intricate details through optical effects. The light pattern creates visual contrast that makes previously unnoticeable surface features visible to the operator, enabling accurate cutting following the projected pattern.
Solution Approach 2:
The system introduces an intermediary light projection mechanism between the reference design and the work-piece surface. This intermediary system (projection device with optical sensor) captures surface features and projects them as a visible light pattern, serving as a mediator that translates invisible details into visible guidance for cutting operations.
2Manufacturing precision
If operators rely on visual inspection of work-piece surface, then cutting decisions can be made, but intricate details are missed leading to reduced quality of resulting structure
Solution Approach 1:
The optical sensor captures light signals reflected from the work-piece surface and creates a digital representation of surface features. This copied information is then processed and projected back onto the surface as a visible light pattern, allowing operators to see details that would otherwise be lost to visual inspection limitations.
Solution Approach 2:
The system establishes a feedback loop where the optical sensor continuously captures surface information, the circuitry processes this data to identify intricate details, and the projection device feeds this information back onto the work-piece surface as a visible light pattern. This feedback mechanism ensures that detail information is preserved and made available to operators throughout the cutting process.
3Manufacturing precision
If no projection system is used, then the system complexity remains low, but operators cannot identify intricate details leading to inaccurate cutting maneuvers
Solution Approach 1:
The projection device serves multiple functions: it projects the light pattern for visibility, the optical sensor captures surface information, and the circuitry processes and determines projection information. This multi-functional integration reduces the need for separate specialized components, thereby managing system complexity while achieving high cutting precision.
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
The system enables operators to clearly identify intricate details, ensuring accurate cutting maneuvers and resulting in a structure with most of the desired features, thus improving the quality of the final product.
Implementation Method 1
capture a first plurality of light signals that may bounce off from the surface of a work-piece
Implementation Method 2
control the projection device to project the pattern of light onto the surface of the work-piece
Data Source
AI summary
A system and a method for projection of a pattern of light on a work-piece are provided. The system includes an optical sensor, circuitry, and a projection device. The circuitry controls the optical sensor to capture a first plurality of light signals that bounces off from a surface of a work-piece and estimates a plurality of surface features of the work-piece based on the captured first plurality of light signals. The circuitry determines projection information for a pattern of light to be projected onto the surface of the work-piece based on the estimated plurality of surface features. Based on the determined projection information, the circuitry controls the projection device to project the pattern of light onto the surface of the work-piece.