Optical Tool Alignment Using Intersecting Viewing Planes
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Solution Overview
Problem
Conventional tool alignment systems rely on depth sensing and visible features, making it difficult to localize tools within a workspace without accurate depth estimation, especially when the tool's position is unknown, and often require human operators to confirm alignment using cameras and laser projections.
Innovation Solution
A tool alignment system using a first optical device (camera) and a second optical device (laser) that project viewing planes, allowing for alignment without depth sensing, where the intersection of these planes is used to determine the tool's position within a workspace, with processors communicating to adjust the tool's position for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If depth sensing is used to establish tool location in workspace, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the depth sensing function from the system by using only 2D image coordinates from a single camera. The tool location is determined by intersecting two viewing planes defined by optical axes and calibration features, eliminating the need for complex depth sensing hardware while maintaining precision through geometric relationships in the 2D image space.
Solution Approach 2:
The patent introduces calibration features as intermediaries between the camera and the tool. These features provide known reference points that allow the system to define viewing planes and determine tool location through geometric intersection calculations, serving as a mediator that enables precise measurement without direct depth sensing.
2Measurement precision
If visible features are required for registration, then measurement precision is improved, but ease of operation worsens
Solution Approach 1:
The patent uses calibration features that create virtual copies or representations of known geometric structures. These calibration features serve as reproducible reference models that define the viewing planes, allowing precise registration through mathematical intersection of planes rather than direct visualization of physical features on the workpiece.
3Measurement precision
If two non-co-located laser projections are used for alignment confirmation, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the alignment confirmation function into the single camera system by using the intersection of two viewing planes. Instead of requiring separate laser projection systems, the alignment is confirmed by calculating where the two planes defined by the camera's optical axes intersect, combining multiple measurement functions into a single integrated system.
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 precise alignment of tools within a workspace without requiring depth estimation, allowing for smaller tool designs and faster, more efficient operations in confined spaces, and reduces the need for human intervention in confirming alignment.
Implementation Method 1
a camera configured to generate an image of a field of view of the camera
Implementation Method 2
a second optical device located adjacent to the camera, the second optical device configured to define a second viewing plane in the image
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A maintenance tool (110) and alignment system are provided having a first optical device (112) and a second optical device (114). The tool (110) includes the at least two optical devices (112, 114) such that they do not occupy the same space or interfere with the tool's function. In some embodiments, the first and second optical devices (112, 114) define or project a first viewing plane (122) and a second viewing plane (124). The first viewing plane (122) and the second viewing plane (124) are transverse to one another and intersect within a field of view of the first optical device (112) creating an intersection (126). The intersection (126) of the first and second viewing planes (122, 124) allows for the tool (110), via a processor (116) or a control device (140), to alignment the tool (110) within a workspace (120) without a dependence on an estimation of a distance of the tool (110) relative to the workspace (120).