Optical Sensor Overview Camera Alignment
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Solution Overview
Problem
Existing optical measuring devices face challenges in reliably and robustly positioning sensors relative to objects, especially for large or complex parts, where visual alignment is difficult due to limited visibility or complex geometries, leading to inaccuracies in measurement data acquisition.
Innovation Solution
A triangulation-based measuring system that incorporates a visual guiding unit with a distinct marker projection, combined with a wide-field overview camera, allows for precise alignment of the sensor by capturing both the measuring light reflection and marker projection, enabling operators to adjust the sensor's position and orientation within a defined measuring range, even in challenging conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a triangulation-based optical sensor is used for measuring large or complex objects, then measurement speed and coverage are improved, but positioning accuracy and alignment reliability deteriorate due to limited visibility and complex geometries
Solution Approach 1:
A visual marker is projected onto the object surface as an intermediary reference element. This marker serves as a mediator between the sensor and the complex object geometry, providing a known reference pattern that the overview camera can reliably detect and use for positioning, even when direct visual alignment with the object features is difficult
Solution Approach 2:
The overview camera continuously captures images of the visual marker and provides real-time feedback about the sensor's position and orientation relative to the object. This feedback loop enables automatic alignment adjustments and ensures the sensor remains within the optimal measuring range, maintaining positioning accuracy during rapid movement
2Ease of operation
If an overview camera with wide field of view is added to capture both marker and measuring light, then alignment capability is improved, but device complexity increases
Solution Approach 1:
The overview camera performs multiple functions: it captures the visual marker for positioning, monitors the measuring light reflection for quality control, and provides operators with a wide-field view of the measurement area. This multi-functionality justifies the addition by delivering multiple benefits from a single component
Solution Approach 2:
The overview camera is integrated with the existing triangulation sensor system, sharing the same housing and coordinate system. The image processing unit combines data from both the overview camera and the triangulation sensor, merging their functionalities into a unified measurement system that achieves enhanced alignment capability without proportionally increasing complexity
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 approach ensures accurate and robust positioning of the sensor, facilitating faster and more precise data capture by providing real-time visual feedback and automatic alignment capabilities, enhancing the reliability of measurements for complex or large objects.
Implementation Method 1
a light emitting unit (11) having a measuring light source for emitting measuring light toward the object
Implementation Method 2
a light receiving unit (12) having a sensor for detecting measuring light reflected from the object
Implementation Method 3
The visual guiding unit (21) comprises a guiding light source for providing a projection of a visual marker onto the object
Data Source
AI summary
A measuring system for triangulation-based distance measuring device having a light emitting unit, a light receiving unit for detecting measuring light reflected from an object and a processing unit for deriving distance information based on a detected reflection of measuring light. The system comprises a visual guiding unit projecting a visual marker onto the object. The light emitting unit and the visual guiding unit provide a light reflection onto the object by emitting the measuring light and the projection of the visual marker onto the object. The measuring system comprises a camera, the field of view of the camera being greater than the field of view of the light receiving unit and the camera captures an image covering the light reflection and the projection of the visual marker and to provide image information according to a captured image.