Light Projector with Sensor Feedback for Construction Alignment
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Solution Overview
Problem
Current augmented reality projection systems in construction face inaccuracies due to registration errors, projector faults, and surface discrepancies between the 'as planned' and 'as built' conditions, leading to inefficient and costly corrections.
Innovation Solution
A system comprising a light projector, sensors, and a computer processor that projects vectors onto construction sites, adjusts projections based on recorded XYZ coordinates, and generates modified projections to align with intended plans, ensuring accurate alignment and adaptation to surface changes and projector errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If APR devices are used to project construction plans in real-time, then build accuracy and efficiency are improved, but registration errors and projector faults cause projection mismatches
Solution Approach 1:
The system continuously monitors the actual projection output and compares it with the intended projection from construction plans. Sensors capture the projected image and feed this information back to the processor, which then generates correction data to compensate for registration errors and projector faults, creating a closed-loop control system that maintains projection accuracy
Solution Approach 2:
The patent replaces manual surveying and measurement processes with an automated optical-electronic system. Instead of using traditional mechanical surveying tools and human operators to verify construction accuracy, the system uses light projection, digital sensors, and computer processing to automatically detect, measure, and correct projection deviations
2Manufacturing precision
If manual surveying and measurement are performed to ensure construction accuracy, then plan divergence is reduced, but the build stage becomes slow and cumbersome
Solution Approach 1:
The system enables continuous verification and correction of construction work without interrupting the build process. Unlike manual surveying that requires stopping work to measure and check, the APR system continuously projects guidance information and automatically corrects for deviations in real-time, allowing construction to proceed without interruption while maintaining accuracy
Solution Approach 2:
The system performs self-verification and self-correction of construction accuracy. The sensors automatically detect projection deviations, the processor calculates corrections, and the system adjusts the projection accordingly without requiring external surveyors or manual measurements, making the accuracy verification process autonomous and instantaneous
3Measurement precision
If registration processes are performed to position the projector accurately, then projection alignment is improved, but the process becomes complex and time-consuming
Solution Approach 1:
The system performs automatic self-registration by using its own projected pattern as the reference. The projector projects a known pattern, sensors capture the actual projection, and the processor automatically calculates the transformation between intended and actual positions. This self-referential approach eliminates the need for external reference features or complex manual registration procedures
4Manufacturing precision
If corrective actions are taken to rectify plan divergence, then construction accuracy is restored, but time and costs increase significantly
Solution Approach 1:
The system performs preliminary correction by continuously monitoring projection deviations and adjusting the projection in real-time before construction errors accumulate. By detecting and compensating for mismatches during the build process rather than after completion, the system prevents plan divergence from developing into significant errors that would require time-consuming corrective actions
Solution Approach 2:
The real-time feedback loop continuously detects projection deviations and automatically adjusts the projection to compensate for errors. This continuous correction prevents small deviations from accumulating into significant plan divergence, eliminating the need for later corrective actions and associated time losses
Data Source
AI summary
A method and a system for projecting a construction plan or a specified pattern in a construction site. The system may include: a light projector configured to project an image associated with the construction plan or the specified pattern, onto a specific surface within the construction site; at least one sensor configured to obtain dimensional parameters of at least one of: the specific surface, and the image as projected on the specific surface; and a computer processor configured to: derive, from the construction plan or the construction pattern, an intended projection portion which comprises visual content intended to be projected on the specific surface; calculate a model of said image, based on the dimensional parameters obtained from the at least one sensor; and generate a modified projection portion based on the model, and the intended projection portion, wherein the light projector is further configured to project said modified projection portion.