Optical Pattern Projector Using Single Diffractive Element
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Solution Overview
Problem
Existing optical pattern projectors for structured-light dimensioning are costly and complex due to the use of two diffractive optical elements (DOEs) or custom laser arrays, necessitating a simpler solution for projecting optical patterns onto objects for accurate dimensioning.
Innovation Solution
An optical pattern projector comprising a laser array, a lenslet array, a lens, and a single diffractive optical element (DOE), where the laser array is arranged in a grid pattern, lenslets focus light into collimated beams, and the DOE creates sub-patterns that combine to form a structured-light pattern, reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two diffractive optical elements (DOEs) are used to create the optical pattern, then the optical pattern can be projected onto the object for dimensioning, but the cost and device complexity increase
Solution Approach 1:
The patent extracts and removes one of the two diffractive optical elements from the system. Instead of using two DOEs to create the optical pattern, the invention uses a single DOE in combination with an f-theta lens, thereby reducing device complexity and cost while maintaining the capability to project structured light patterns for accurate dimensioning
Solution Approach 2:
The patent introduces an f-theta lens as an intermediary component between the light source and the single DOE. This intermediary element helps to collimate the laser beams and work in conjunction with the DOE to achieve the desired optical pattern projection, replacing the need for the second DOE while preserving measurement precision
2Measurement precision
If a custom laser array is used to form the sub-pattern of light, then the optical pattern can be created, but the cost and device complexity increase
Solution Approach 1:
The patent replaces expensive custom laser arrays with standard, off-the-shelf VCSEL arrays. These conventional laser sources are significantly cheaper and easier to manufacture while still providing sufficient performance for structured light dimensioning when combined with the f-theta lens and single DOE configuration
3Measurement precision
If two diffractive optical elements (DOEs) are used to create the optical pattern, then the optical pattern can be projected onto the object for dimensioning, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and removes one of the two diffractive optical elements from the system. Instead of using two DOEs to create the optical pattern, the invention uses a single DOE in combination with an f-theta lens, thereby reducing device complexity and cost while maintaining the capability to project structured light patterns for accurate dimensioning
Solution Approach 2:
The patent introduces an f-theta lens as an intermediary component between the light source and the single DOE. This intermediary element helps to collimate the laser beams and work in conjunction with the DOE to achieve the desired optical pattern projection, replacing the need for the second DOE while preserving measurement precision
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
This configuration enables efficient and cost-effective projection of structured-light patterns for accurate dimensioning, allowing for precise measurement of object dimensions using a handheld system with improved optical pattern generation and reduced component complexity.
Implementation Method 1
The lenslet array is positioned in front of the laser array to focus the radiated light from the lasers into a plurality of collimated laser beams
Implementation Method 2
The lens redirects each laser beam along a particular incident angle determined by the laser beam's spatial position in the grid pattern
Implementation Method 3
The DOE receives all of the laser beams and, for each laser beam, creates a sub-pattern. The DOE projects each sub-pattern along a particular angle determined by the particular laser beam's incident angle
Data Source
AI summary
An optical pattern projector used for projecting a structured-light pattern onto an object for dimensioning is presented. The optical pattern projector utilizes a laser array, a lenslet array, a lens, and a diffractive optical element to create a repeated pattern of projected dots. The pattern repetition is based on the grid pattern of laser array. Each laser's collimated beam, when projected through the lens, impinges on the diffractive optical element from a slightly different direction. The diffractive optical element creates a sub-patterns that continue propagating along these different directions and combine on a target to produce a repeating optical pattern.