Optical Projection System for Construction Plan Visualization
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Solution Overview
Problem
The manual assembly of structural elements in construction processes, particularly with precast concrete elements, is time-consuming and prone to errors, leading to potential structural integrity issues and safety risks due to incorrect positioning or omission of components, which results in costly rework and delays.
Innovation Solution
A method utilizing a raster reflection technique with a projection unit and sensor units to project a plan in real dimensions, correcting for surface curvature and position, allowing precise assembly without manual measurement, and incorporating augmented reality for additional information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly of structural elements is performed according to construction plans, then workers can assemble elements with flexibility and adaptability, but the process becomes time-consuming and prone to positioning errors
Solution Approach 1:
The patent replaces manual mechanical measurement and positioning with an optical projection system. A projection unit projects construction plans directly onto the work surface, allowing workers to visually identify exact positions without manual measurement. This substitution of mechanical measurement methods with optical projection technology simultaneously improves positioning precision and reduces assembly time.
Solution Approach 2:
The patent creates a visual copy of the construction plan by projecting it onto the actual work surface. This projected image serves as a direct visual guide that replicates the dimensional relationships and positioning information from the original plan, eliminating the need for workers to interpret and manually transfer measurements, thereby reducing both time and positioning errors.
2Manufacturing precision
If construction plans are projected onto curved or inclined surfaces without correction, then the projection process is simple and fast, but the projected plan becomes distorted and inaccurate
Solution Approach 1:
The patent employs sensor units that detect the actual geometry of the projection surface (curvature and inclination). This detection information is fed back to a control unit, which then calculates and applies appropriate distortion correction to the projected image. The feedback loop ensures that the projected plan accurately represents the construction dimensions even on non-flat surfaces, maintaining precision while managing system complexity through automated correction.
Solution Approach 2:
The patent dynamically adjusts projection parameters based on detected surface characteristics. The control unit modifies the projection data by applying distortion corrections that compensate for surface curvature and inclination. By changing the projection parameters (image distortion, scaling, positioning) based on detected surface conditions, the system maintains accurate dimensional representation without requiring complex physical projection adjustments.
3Manufacturing precision
If multiple sensor units are used to detect surface geometry for accurate projection correction, then projection accuracy on curved surfaces is improved, but the device complexity and calibration requirements increase
Solution Approach 1:
The patent designs the sensor units to perform multiple functions: detecting surface curvature, measuring inclination angles, and providing spatial positioning information for projection alignment. By making the sensor system multi-functional, the patent reduces the need for separate detection devices and minimizes overall system complexity while maintaining high detection accuracy for projection correction.
Solution Approach 2:
The patent introduces a control unit that acts as an intermediary between the sensor units and the projection unit. This control unit processes the raw detection data from multiple sensors, performs the necessary calculations for distortion correction, and generates the corrected projection image. The intermediary control unit simplifies the system architecture by centralizing the complex processing logic, making the overall system more manageable despite using multiple sensors.
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
Ensures accurate and efficient assembly by projecting undistorted plans directly onto surfaces, reducing errors, enhancing safety, and optimizing construction processes through automated verification and correction of element placement.
Implementation Method 1
using a raster reflection method, a transmitted pattern is projected onto a projection surface by means of a projection unit
Implementation Method 2
a received pattern reflected from the projection surface is detected by at least two sensor units
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3b
AI summary
A method for visualizing a plan in real dimensions, wherein, within the scope of a calibration step and using a grid reflection method, a transmission pattern is projected onto a projection surface (5) by means of a projection unit (2) and a reception pattern reflected by the projection surface (5) is detected by at least two sensor units (3), and a computer unit (4) connected to the projection unit (2) and the sensor units (3) is used to detect a surface shape and a relative position of the projection surface (5) in relation to a position of the projection unit (2) and in relation to a position of the sensor units (3) on the basis of a distortion of the reception pattern in comparison with the transmission pattern, and the computer unit (4) is used to apply a projection distortion to the plan on the basis of the surface shape and relative position of the projection surface (5) in relation to the projection unit (2) detected in the calibration step, and the distorted plan is projected by the projection unit (2) onto the projection surface (5) in such a way that the projected plan (13) on the projection surface (5) corresponds to a non-distorted, planar representation of the plan in real dimensions.