Line-Laser Key Tooth Profile Learning for Accurate 3D Duplication
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Solution Overview
Problem
Existing non-contact key tooth profile learning methods have issues with universality, environmental requirements, operational complexity, and efficiency due to high assembly accuracy needs for photoelectric sensors and mechanical structures, limiting their applicability and accuracy.
Innovation Solution
A non-contact key tooth profile learning method using a line laser to acquire and process 3D profile information, enabling machining accuracy evaluation and compensation, with a system comprising an image acquisition module for point cloud data and processing modules for 3D reconstruction and machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If opposite-type photoelectric sensors are used for tooth profile measurement, then non-contact measurement is achieved, but high assembly accuracy and environmental requirements are needed
Solution Approach 1:
The patent replaces the mechanical assembly of opposite-type photoelectric sensors with a line laser projection system combined with a single camera. This substitution eliminates the need for precise mechanical alignment of multiple sensors, as the line laser directly projects measurement patterns onto the key surface and the camera captures the deformed patterns for analysis, significantly reducing assembly complexity while maintaining measurement precision.
Solution Approach 2:
The patent uses a line laser to project a reference pattern (copy of known geometry) onto the key surface. By comparing the projected pattern with the actual reflected light captured by the camera, the system measures tooth profile deviations without requiring complex sensor assemblies. This copying approach simplifies the measurement system while achieving high precision.
2Measurement precision
If opposite-type photoelectric sensors are used for tooth profile measurement, then non-contact measurement is achieved, but protection performance of optical lens and environmental requirements are increased
Solution Approach 1:
The patent replaces the vulnerable optical lens system of photoelectric sensors with a line laser projection system. The line laser emits structured light patterns that are more robust to environmental conditions, and the camera captures the patterns without requiring protective lenses, thereby reducing environmental constraints and harmful factor susceptibility.
3Measurement precision
If high assembly accuracy is required for photoelectric sensors, then measurement accuracy is improved, but operation complexity and efficiency are reduced
Solution Approach 1:
The patent replaces the complex mechanical alignment and calibration procedures of photoelectric sensors with a line laser system that inherently provides accurate measurement patterns. The system requires minimal setup and calibration, as the line laser automatically projects reference patterns that can be directly captured and analyzed, significantly simplifying operations while maintaining high accuracy.
4Measurement precision
If opposite-type photoelectric sensors are used for tooth profile measurement, then non-contact measurement is achieved, but productivity is reduced
Solution Approach 1:
The patent enables continuous measurement of tooth profiles by using a line laser that projects patterns across the entire key surface in a single action, rather than requiring multiple sensor positions or sequential measurements. The camera captures the complete pattern simultaneously, allowing rapid data acquisition and processing, thereby improving productivity while maintaining measurement accuracy.
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 method achieves high learning accuracy and machining precision, improving universality and efficiency by reducing environmental and operational complexities, and allowing for accurate key duplication across various key types without the need for probe replacement.
Implementation Method 1
projecting a single beam of line laser on the surface of the key successively in multiple viewing angles for translational scanning, and receiving the reflected laser reflected from the surface of the key
Data Source
AI summary
A non-contact key tooth profile learning method and system are provided. The non-contact key tooth profile learning method comprises the following steps: acquiring first profile point cloud data of a key by means of a line laser method; and processing the first profile point cloud data so as to obtain first 3D profile information.