Optical Sensor Alignment Using Superimposed Projection Images
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical sensors for detecting marks like barcodes or 2D codes require complex and expensive diffractive optical elements for alignment, which are static and require separate manufacturing for each optics variant, leading to high costs and structural complexity.
Innovation Solution
The use of two projection means arranged differently relative to the image sensor, generating superimposed projection images that provide visual feedback on the object's position and distance, allowing for easy alignment without mechanical adjustments, using either LCD or OLED arrangements for flexible and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a diffractive optical element with a laser is used for alignment verification, then the reading distance setting can be visually checked, but the structural complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces the complex diffractive optical element with a simple projection means that projects a reference image (such as a circle or grid pattern) onto the object. This reference image serves as a visual copy or indicator that directly shows the reading distance setting, eliminating the need for complex diffractive optics while achieving the same verification function
Solution Approach 2:
The patent uses inexpensive projection means (such as simple lenses or even basic projection mechanisms) instead of costly diffractive optical elements. These simple projection components can be easily manufactured and replaced, significantly reducing both manufacturing costs and structural complexity while maintaining the alignment verification capability
2Measurement precision
If a diffractive optical element is used for alignment, then the reading distance can be verified, but substantial tooling costs are incurred for manufacturing
Solution Approach 1:
The patent uses a simple projection means to project a reference image that copies or represents the reading distance information. This approach replaces expensive diffractive optical elements with basic projection components that have minimal tooling costs and can be manufactured using standard processes
Solution Approach 2:
The projection means used in the patent consists of simple, inexpensive components that can be easily manufactured without substantial tooling investments. These components may include basic lenses or even simple projection mechanisms that can be produced at low cost using conventional manufacturing methods
3Measurement precision
If a diffractive optical element is used for alignment verification, then the reading distance can be checked, but a new element is required for each optical variant, increasing costs
Solution Approach 1:
The patent employs a universal projection means that can be used across different optical variants of the sensor. The projection mechanism and reference image design are made adaptable to various optical configurations, allowing a single type of projection means to serve multiple optical variants without requiring separate diffractive elements for each variant
Solution Approach 2:
The patent introduces dynamic adaptability by allowing the projection means to be adjusted or configured for different optical variants. This may involve adjustable projection parameters, interchangeable but standardized projection components, or software-controlled projection patterns that can adapt to different optical configurations, providing versatility without requiring completely separate hardware for each variant
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 simplifies the alignment process, reduces production costs, and allows for adaptable projection images that can be easily adjusted electronically, enabling precise detection of marks within the reading range without the need for complex diffractive optical elements.
Implementation Method 1
The projection means are in each case formed by an LCD arrangement or an OLED arrangement
Implementation Method 2
receiving optics to direct light rays reflected from an object to be detected onto the image sensor
Implementation Method 3
the reading distance is defined by the focal point of the receiving optics
Data Source
Figure 1
Figure 2~3
Figure 4a~5c
AI summary
The invention relates to an optical sensor for detecting objects and comprises a receiving unit (2) with at least one image sensor (3) and an illumination unit associated with the image sensor (3). The illumination unit has at least two projection means (5) arranged in different positions relative to the image sensor (3), each of which generates a projection image. The projection images are designed such that the degree of superposition of the projection images projected onto an object visualizes whether the object is located within a reading field and/or reading distance (D) to the image sensor (3) or not.