Multi-line Array Laser 3D Scanning Synchronization
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Solution Overview
Problem
Current three-dimensional laser scanning technologies face challenges such as low scan efficiency and high cost, short service life due to light attenuation and heat dissipation issues, high mismatching rates, and low accuracy due to reliance on operator-controlled working distance.
Innovation Solution
A multi-line array laser three-dimensional scanning system utilizing a programmable gate array FPGA, stereoscopic image sensors, inertial sensors, and an error feedback controller to synchronize and control the scanning process, enabling real-time error evaluation and adjustment for precise synchronization and logic control, and employing hybrid sensor locating technology for high accuracy and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single-line laser scanning technology is used, then cost is low and structure is simple, but scanning speed is slow and scanning efficiency is limited
Solution Approach 1:
The patent divides the single laser line into multiple parallel lines by using a diffraction grating, creating a multi-line array laser scanning system. This segmentation allows simultaneous scanning of multiple lines, dramatically increasing scanning speed while maintaining the simplicity of the original laser source structure.
Solution Approach 2:
The patent introduces a temporal dimension to the scanning process by using pulsed laser illumination synchronized with camera exposure. This allows multiple lines to be captured in a single pulse sequence, transforming the scanning process from sequential to parallel operation without adding complex spatial mechanisms.
2Productivity
If continuous full-power scanning is performed, then scanning efficiency is high, but light attenuation accelerates and service life shortens
Solution Approach 1:
The patent employs pulsed laser illumination instead of continuous emission, synchronizing laser pulses with camera exposure periods. This periodic action allows the laser and optical components to rest between pulses, reducing cumulative light exposure and thermal buildup, thereby extending service life while maintaining high scanning efficiency during active periods.
3Productivity
If continuous full-power scanning is performed, then scanning efficiency is high, but heat generation increases and cooling problems arise
Solution Approach 1:
The pulsed operation mode creates periodic intervals between high-power emissions, allowing heat to dissipate during off-periods. This prevents continuous thermal accumulation in the laser diode and optical components, eliminating the need for complex cooling systems while maintaining high scanning efficiency during pulse periods.
4Measurement precision
If working distance is controlled manually by operator, then device complexity is low, but scanning accuracy is reduced and reliability is low
Solution Approach 1:
The patent incorporates a feedback mechanism where the system automatically adjusts working distance based on real-time evaluation of scanning quality metrics. The controller monitors focus accuracy and depth of field coverage, then dynamically adjusts the distance between the laser array and object surface to maintain optimal scanning conditions, significantly improving accuracy without requiring complex manual intervention.
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 achieves low-cost, high-efficiency, and high-accuracy scanning with improved reliability and extended service life by reducing mismatching rates and enhancing scanning accuracy to 0.03mm, as per international standards.
Implementation Method 1
a line laser array, configured to send a first trigger signal to the line laser array, so that the line laser array illuminates the surface of a measured object with stroboflash according to the first trigger signal
Implementation Method 2
send a second trigger signal to the stereoscopic image sensor, so that the stereoscopic image sensor performs exposure shootings to the measured object according to the second trigger signal
Data Source
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AI summary
The present invention provides a multi-line array laser three-dimensional scanning system and a multi-line array laser three-dimensional scanning method, the system performs precise synchronization and logic control of the multi-line array laser three-dimensional scanning system by a programmable gate array FPGA; employs a line laser array as the projection pattern light source, sends trigger signals to a stereoscopic image sensor, a inertial sensor and a line laser array by FPGA; wherein a upper computer receives image pairs taken by the stereoscopic image sensor, and codes, decodes as well as performs a three-dimensional reconstruction for the laser line array patterns in the image pairs, performs a three-dimensional reconstruction for the feature points on the surface of the measured object, and matches and aligns the three-dimensional feature points at different times; the system predicts and corrects the matching calculation by employing a hybrid sensing technology, which registers and stitches the time domain laser three-dimensional scanning data, meanwhile evaluates the error level in real time and feeds it back to an error feedback controller to obtain an adjustment instruction. Thereby the system performs a laser three-dimensional scanning with low cost, high efficiency, high reliability and high accuracy.