Portable 3D Metrology Instrument with Surface Projection
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Solution Overview
Problem
Existing optical metrology instruments face challenges in providing quick, accurate, and versatile 3D surface measurements in harsh environments, such as factories and fields, where they must be portable, rugged, and able to display results directly on the measured surface due to vibrations, temperature fluctuations, and limited space, while avoiding parallax errors and allowing multiple users to view the results simultaneously.
Innovation Solution
A non-contact 3D surface metrology instrument that projects measurement results directly onto the target surface, using a result-image generator for false-color representations and text, with adjustable colors and layouts, and incorporates inertial measurement units to correct for motion and ensure precision, featuring compact, lightweight, and self-contained designs with LED illumination and MEMS-based image generation for fast and accurate results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If measurement results are displayed on a separate screen, then the display can show detailed measurement data, but the operator must look back and forth between the screen and the target object, consuming time and creating opportunities for mistakes
Solution Approach 1:
The measurement results are projected onto the target surface itself, transitioning the display from a separate 2D screen to a 3D augmented reality overlay on the object. This allows operators to view measurement data directly where it is needed, eliminating the need to look back and forth between a separate display and the target object, thus resolving the contradiction between detailed data display and operator efficiency
2Ease of operation
If head-mounted displays are used to show measurement results, then the operator can view results without looking back at a separate screen, but they may create parallax errors or obscure peripheral vision too much for safety
Solution Approach 1:
The system uses the target surface itself as an intermediary display medium, projecting measurement results directly onto it. This eliminates the need for head-mounted displays that cause parallax errors or obscure peripheral vision. The target surface acts as the intermediary that carries the measurement information without interfering with the operator's safety or comfort, thus resolving the contradiction between viewing convenience and reliability
3Weight of moving object
If a portable instrument is designed to be compact and lightweight, then it can be easily moved between locations, but it may have reduced measurement capability or durability
Solution Approach 1:
The instrument replaces traditional mechanical scanning methods with optical projection and capture systems. By using projected structured light patterns and digital image processing, the system achieves high measurement accuracy without requiring complex mechanical scanning mechanisms, thereby reducing weight while maintaining reliability in harsh environments
4Adaptability or versatility
If the instrument is designed to be rugged and portable for field use, then it can withstand vibrations and temperature fluctuations, but it may have reduced measurement precision
Solution Approach 1:
The system dynamically adjusts measurement parameters such as projection pattern frequency, illumination intensity, and image capture rate based on environmental conditions. By adapting these parameters in real-time to compensate for vibrations and temperature fluctuations, the instrument maintains high measurement precision while remaining portable and rugged for field use
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 real-time, accurate, and versatile 3D surface measurements that can be viewed directly on the surface, reducing ambiguity and allowing multiple users to see results without obstructing their vision, while being portable and resistant to environmental challenges, ensuring high precision and ease of use.
Implementation Method 1
Optical approaches such as laser scanning and structured-light projection are popular for their speed, non-invasiveness, and acceptable precision and accuracy
Implementation Method 2
The same camera used to capture measurement-pattern images may also capture projected result-images for archival
Implementation Method 3
Light-emitting diodes (LEDs) providing the illumination are small, lightweight, durable, long-lasting, and require little or no cooling
Implementation Method 4
Some embodiments have few or no significantly moving parts, using liquid-crystal or microelectromechanical systems (MEMS) to generate the measurement patterns and the result-images
Implementation Method 5
The projection of this image is corrected for distortions introduced by the projector and the target surface
Data Source
AI summary
A portable instrument for 3D surface metrology projects augmented-reality feedback directly on the measured target surface. The instrument generates structured-light measuring-patterns and projects them successively on a target surface. Features, contours, and textures of the target surface distort each projected measuring-pattern image (MPI) from the original measuring-pattern. The instrument photographs each MPI, extracts measurement data from the detected distortions, and derives a result-image from selected aspects of the measurement data. The instrument warps the result-image to compensate for distortions from the projector or surface and projects the result-image on the measured surface, optionally with other information such as summaries, instrument status, menus, and instructions. The instrument is lightweight and rugged. Accurate measurements with hand-held embodiments are made possible by high measurement speed and an optional built-in inertial measurement unit to correct for pose and motion effects.