Optical 3-Axis Sensor Using Geometric Shape Projection
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Solution Overview
Problem
Conventional multi-axis sensors, particularly two-axis systems like joysticks, face issues with durability and sensitivity, where they either fail under high forces or are unresponsive to low forces, and are difficult to clean and disinfect, especially in medical settings, due to mechanical wear and protective rubber components.
Innovation Solution
An optical, adaptive three-axis sensor system that projects a geometric shape onto an image sensor, allowing for real-time adjustment to desired input forces and movement ranges, using a projection unit connected to a force-absorbing element, which calculates X, Y, and Z coordinates based on distortion, enabling high-resolution output signals and easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mechanical sensor systems are designed to be robust for high forces, then durability is improved, but sensitivity to low forces deteriorates
Solution Approach 1:
The patent replaces mechanical sensor systems with an optical system consisting of a projection unit, image sensor, and evaluation unit. This substitution eliminates mechanical wear and tear while maintaining the ability to detect forces across a wide range, from very low to very high forces, thereby resolving the contradiction between durability and sensitivity.
2Reliability
If protective rubber components are added to prevent ingress of foreign matter, then reliability is improved, but ease of cleaning deteriorates
Solution Approach 1:
By replacing the mechanical sensor system with an optical system, the patent eliminates rubber bellows and protective rubbers that are difficult to clean. The optical components can be easily cleaned and disinfected, especially important for medical applications, while maintaining protection against foreign matter through the sealed design of the projection unit and image sensor.
3Ease of manufacture
If mechanical sensor systems are used, then ease of manufacture is improved, but productivity deteriorates due to wear and tear
Solution Approach 1:
The patent replaces mechanical sensing mechanisms with an optical system that has no moving parts subject to wear. The projection unit projects a geometric pattern onto a target, and the image sensor captures the pattern. This eliminates mechanical wear and tear entirely, significantly extending the operational lifespan while maintaining ease of manufacture through standardized optical components.
4Measurement precision
If optical systems with light sensors are used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a single image sensor to measure positions in three-dimensional space (X, Y, Z coordinates) by analyzing the distortion of a projected geometric pattern. This multi-functional approach allows the system to achieve high measurement precision while avoiding the complexity of multiple separate sensors or complex mechanical structures, as the evaluation unit processes the pattern distortion to extract all spatial information.
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 provides high accuracy, resistance to wear, and adaptability to varying user forces, ensuring reliable operation across different applications with improved cleaning and disinfection capabilities, and increased resolution through image analysis and interpolation.
Implementation Method 1
A light source (e.g. LED or laser) is assigned to the projection unit; for example includes the projection unit itself the light source
Implementation Method 2
forces acting on the force absorption produce an inversely exponential deflection of the projected image on the image sensor
Data Source
AI summary
A device for determining the position of a force-absorbing element (2) in three axes comprises a high-resolution image sensor (6), a movement support (4) which is arranged opposite the image sensor and is connected to the force-absorbing element (2), a projection device (3) which is connected to the movement support (4) and projects, onto the image sensor, a predefined geometric shape (10) which is positioned and distorted according to an x/y/z inclination of the movement support. A computing device (7) derives, from the position and distortion of the geometric shape (10), high-resolution x/y/z coordinates for further processing.