Optical Indicator System for Manual Assembly Alignment
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Solution Overview
Problem
Existing optical projection systems for manual assembly and manufacturing tasks face limitations in rapid alignment, operator feedback, and efficient control of work tasks, particularly when operators are remote from the controller, due to issues like flicker, complex remote-control devices, and the need for clear projection surfaces.
Innovation Solution
A method and system that uses a measurement system to track control objects and project optical indicators on a worksurface, allowing operators to control and receive real-time feedback on work tasks through manipulation of these objects, enabling efficient progression and completion of tasks without the need for complex remote controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional laser projection systems are used with retro-reflective targets for alignment, then manufacturing precision is improved, but device complexity and resource requirements increase
Solution Approach 1:
The patent extracts the alignment function from complex physical target systems and implements it through software-based virtual alignment references projected by the laser system itself. This eliminates the need for separate retro-reflective targets and complex measurement equipment, reducing device complexity while maintaining alignment precision through the projected alignment patterns that operators can visually reference.
Solution Approach 2:
The patent creates virtual copies of alignment references by projecting laser patterns that replicate the function of physical targets. Instead of requiring physical retro-reflective targets, the system projects optical patterns that serve as alignment guides, simplifying the overall system while preserving the alignment capability.
2Ease of operation
If operators use remote-control devices to control projection systems from a distance, then ease of operation is improved, but device complexity increases due to multiple buttons and controls
Solution Approach 1:
The patent implements self-service control where the projection system automatically responds to operator actions without requiring complex remote control interfaces. The system detects operator presence and actions, and automatically adjusts projections or provides feedback, eliminating the need for complicated remote controls with multiple buttons and switches.
Solution Approach 2:
The projection system serves multiple functions including alignment guidance, task instructions, and control feedback through a single integrated interface. This multi-functionality eliminates the need for separate complex remote control devices, as the projection system itself provides all necessary control and feedback mechanisms.
3Productivity
If laser beams are scanned at high speed to create stable images, then productivity is improved, but measurement precision of operator interactions decreases
Solution Approach 1:
The patent uses periodic scanning of laser beams at high speed to create persistent visual images for productivity, while incorporating separate periodic measurement cycles where the system pauses or intersperses low-speed scanning periods dedicated to detecting operator interactions. This periodic alternation between high-speed imaging and precision detection maintains both productivity and 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
Enables operators to control and monitor work tasks in real-time from a remote location, improving efficiency and usability by providing accurate tracking and feedback of task implementation and completion, even when operators are distant from the controller.
Implementation Method 1
A measurement system monitored a work area in which the worksurface was disposed. The measurement system located a control object within the work area and identified a marker disposed on the control object.
Implementation Method 2
A projection device projected a first optical indicator and a second optical indicator onto the worksurface
Implementation Method 3
The laser projector 10 is registered to a worksurface 12 of a workpiece 14 by placing retro-reflective targets 16 at precisely measured locations on the worksurface 12. The retro-reflective targets 16 are scanned by mirrors of a scanning system included in the laser projector 10
Data Source
AI summary
A method and system for controlling projection of optical indicators on a worksurface is disclosed. A projection device for projecting a first optical indicator and a second optical indicator onto a worksurface is provided. A measurement system monitors a work area in which the worksurface is disposed. The measurement system locates a control object within the work area and identifies a marker disposed on the control object. The measurement system monitors a first disposition and a second disposition of the control object. The projection device projects the first optical indicator onto the worksurface and the projection device projects the second optical indicator onto the worksurface in response to manipulation of the control object between the first disposition and the second disposition as detected by said measurement system.