MEMS Laser Surface Defect Detection for Handheld 3D Scanning

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Solution Overview

Problem

Existing 3D scanning technologies for detecting damage on aircraft surfaces are hindered by large size, high power consumption, high cost, and low measurement precision, particularly in the context of portable, handheld devices for detecting minor damages.

Innovation Solution

A detection module utilizing MEMS micro scanning mirrors and a RGB image sensor for 3D scanning, combined with a processor to stitch laser and RGB images, and a pattern projecting device to highlight defects, integrated within a compact handheld device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If DLP-based 3D scanning solution is used, then measurement precision is improved, but device size and weight increase significantly

Engineering Contradiction:

Improvemeasurement precisionVSAvoiddevice weight

Core Design Contradiction:

Measurement precisionVSWeight of moving object

Solution Approach 1:

The patent replaces the mechanical DLP projection system with a laser-based scanning system using MEMS mirrors. Instead of using a complex digital light processing engine that requires large optical components, the invention uses a laser source combined with micro-electro-mechanical system mirrors to scan and project laser lines onto the surface, achieving precise 3D measurement with significantly reduced device size and weight.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If DLP-based 3D scanning solution is used, then measurement precision is improved, but power consumption increases

Engineering Contradiction:

Improvemeasurement precisionVSAvoidpower consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent replaces the power-intensive DLP projection system with a more energy-efficient laser-based scanning system. The laser source consumes significantly less power than a DLP engine, and the MEMS mirrors require minimal actuation power compared to the mechanical shutters and projection optics of a DLP system, thereby reducing overall power consumption while maintaining measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If DLP-based 3D scanning solution is used, then measurement precision is improved, but device cost increases

Engineering Contradiction:

Improvemeasurement precisionVSAvoiddevice cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the expensive DLP engine and its associated optical components with a more cost-effective laser-based system. The laser source, MEMS mirrors, and simple optical elements required for laser line scanning are significantly cheaper than a DLP projection engine, reducing the overall device cost while achieving comparable or superior measurement precision for surface inspection applications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Volume of moving object

If MEMS-based 3D scanning solution is used, then device size is reduced, but measurement precision deteriorates

Engineering Contradiction:

Improvedevice volumeVSAvoidmeasurement precision

Core Design Contradiction:

Volume of moving objectVSMeasurement precision

Solution Approach 1:

The patent optimizes key parameters of the MEMS-based system including the laser wavelength, laser power, MEMS mirror scanning frequency and angle, and camera exposure settings. By carefully adjusting these parameters, the system achieves high measurement precision despite the compact form factor. The multi-line laser projection and image stitching algorithms further enhance precision while maintaining a small device volume.

Inventive Principle:

Principle #35Parameter changes

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

Improves detection efficiency, standardizes measurement operations, and reduces device volume while enhancing precision and user experience.

Implementation Method 1

at least two MEMS micro scanning mirrors configured to reflect laser emitted by the laser source onto the detected surface

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a laser receiving device configured to receive the reflected laser from the detected surface to obtain at least two laser images of the detected surface

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 3

a RGB image sensor configured to capture a RGB image of the detected surface

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20250362238A1Detection module, detection device, detection system, and detection method

Publication Date: 2025.11.27 AIRBUS (SAS)

AI summary

Disclosed are a detection module, a detection device, a detection system, and a detection method. The detection module includes a scanning unit configured to perform 3D scanning on a detected surface and having a laser projecting device including a laser source and at least two MEMS micro scanning mirrors configured to reflect laser emitted by the laser source onto the detected surface, and a laser receiving device configured to receive the reflected laser from the detected surface to obtain at least two laser images of the detected surface; a RGB image sensor configured to capture a RGB image of the detected surface; and a processor connected to the scanning unit and the RGB image sensor, and configured to stitch the at least two laser images, and detect a defect of the detected surface based on the stitched laser image and the RGB image.