Multi-polygon Laser Scanner with Stacked Offset Facets
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Solution Overview
Problem
Existing polygon-based laser scanning systems face challenges in achieving a compact size while maintaining scanning efficiency and generating a desired field of view, as increasing the beam diameter requires longer mirrored facets, leading to a larger system size, and increasing the number of facets increases the overall size, making it unsuitable for space-constrained applications.
Innovation Solution
Implementing a multi-polygon arrangement with rotationally offset and stacked polygons, along with a separator to direct light pulses vertically and horizontally, allowing for a smaller and more compact design that maintains scanning efficiency and generates a desired field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the beam diameter is increased to improve field of view, then the scanning coverage is improved, but the system size increases due to longer mirrored facets required
Solution Approach 1:
The patent divides a single large polygon into multiple smaller polygons (e.g., first polygon with 5 facets, second polygon with 5 facets) that are rotationally offset and stacked. Each polygon handles a portion of the scanning task, allowing the system to achieve the same or greater field of view with smaller individual components, thus reducing overall system size while maintaining scanning coverage.
Solution Approach 2:
The patent transitions from a single-plane (2D) polygon arrangement to a multi-plane (3D) stacked configuration. By stacking polygons vertically along the beam path with rotational offsets, the system achieves expanded field of view in multiple dimensions without requiring each individual polygon to be large, thereby decoupling field of view from system size.
2Productivity
If the number of facets is increased to improve scanning efficiency, then the angular coverage is improved, but the overall polygon size and system complexity increase
Solution Approach 1:
Instead of using one polygon with many facets, the patent segments the scanning function across multiple polygons with fewer facets each. For example, two polygons with 5 facets each can achieve the same angular coverage as one polygon with 10 facets, but with reduced individual size and simplified manufacturing for each component.
Solution Approach 2:
The patent combines multiple smaller polygons into a unified scanning system where their collective facets provide the total required angular coverage. The rotationally offset stacking arrangement merges their scanning functions to achieve comprehensive coverage equivalent to or better than a single large polygon, while keeping individual component sizes manageable.
3Area of stationary object
If a single large polygon is used to achieve desired field of view, then the scanning coverage is sufficient, but the system becomes unsuitable for space-constrained applications
Solution Approach 1:
The patent segments the single large polygon into multiple smaller polygons that can be compactly stacked. This segmentation allows the system to maintain adequate scanning coverage while fitting into space-constrained applications, as the smaller stacked polygons occupy less overall volume than a single large polygon would require.
Solution Approach 2:
The patent implements a nested-like configuration where multiple polygons are stacked along the beam path in a compact arrangement. The rotationally offset stacking creates a space-efficient configuration where polygons are positioned in sequence along the optical axis, maximizing space utilization and enabling deployment in space-constrained environments while maintaining scanning coverage.
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 multi-polygon arrangement enables a smaller and more compact laser scanning system that achieves the desired field of view and scanning efficiency, while maintaining the optically-fast saw-tooth scanning pattern, addressing the size constraints of traditional single-polygon systems.
Implementation Method 1
light emitted by a pulsed laser and directed toward the polygon reflects off of the rotating outwardly-facing mirrored facets of the polygon in a saw-tooth pattern
Data Source
AI summary
Multi-polygon, vertically-separated laser scanning apparatus and methods are disclosed. An example apparatus includes a multi-polygon. The multi-polygon includes a first polygon, a central axis, and a second polygon. The first polygon includes a first plurality of outwardly-facing mirrored facets. The second polygon includes a second plurality of outwardly-facing mirrored facets angularly offset about the central axis relative to the first plurality of outwardly-facing mirrored facets. The second polygon is positioned relative to the first polygon along the central axis. The first and second polygons are rotatable about the central axis.