Probe Scanner for Restricted Cavity Surfaces
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Solution Overview
Problem
Current three-dimensional scanning technologies face challenges in achieving high precision for interior surfaces, particularly in limited or restrictedly accessible areas like the human ear and ear canal, due to systematic or random errors in calibration and performance, which is critical for applications such as hearing aids and dental implants.
Innovation Solution
A method and scanner system using a probe-shaped scanner with a light source and camera that projects structured light and records 2D images to generate 3D coordinates, capable of scanning interior surfaces by varying the focus plane and combining images to fill gaps in data, even in obstructed areas, and utilizing additional data sources for interpolation, allowing for direct scanning without impressions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional scanner is used to scan interior surfaces, then the scanning process is simple, but the measurement precision and manufacturing precision deteriorate due to systematic or random errors in calibration and performance
Solution Approach 1:
The scanning system is divided into multiple independent modules: multiple light sources projecting different structured light patterns, multiple cameras positioned at different angles, and separate data processing units. Each module can be calibrated and optimized independently, reducing systematic errors while maintaining high precision measurements of interior surfaces.
Solution Approach 2:
The patent implements a probe-shaped scanner that can be inserted into the cavity being scanned, nesting the scanning system within the measurement space. This allows the scanner to get close to the interior surfaces without requiring external positioning equipment, thereby improving measurement precision while keeping the overall device configuration manageable.
2Loss of information
If the scanner is moved relative to the object to scan the full object, then the complete surface is covered, but the productivity decreases due to time-consuming manual or mechanical repositioning
Solution Approach 1:
The patent employs dynamic repositioning mechanisms that allow the scanner to automatically adjust its position and orientation within the cavity. Multiple cameras and light sources are arranged to cover different angular positions, and the system dynamically activates appropriate subsets based on the current viewing angle, enabling complete surface coverage without physical repositioning of the entire scanner assembly.
Solution Approach 2:
The scanning system continuously captures surface data from multiple angles simultaneously using multiple cameras and light sources. Rather than stopping to reposition between measurements, the system maintains continuous operation with overlapping fields of view, ensuring complete surface coverage while maximizing scanning speed and productivity.
3Measurement precision
If multiple light sources and cameras are used to improve precision, then the measurement precision improves, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent designs the scanner with universal, modular components where multiple light sources and cameras use standardized mounting interfaces, calibration procedures, and data processing protocols. Each camera-light source pair functions as an independent measurement unit that can be manufactured separately and assembled systematically, reducing manufacturing complexity despite the multi-component configuration.
4Ease of operation
If the probe-shaped scanner is inserted into the cavity, then the accessibility to restricted areas is improved, but the device complexity increases due to the specialized probe structure
Solution Approach 1:
The scanning system is nested within a compact probe-shaped housing that can be inserted into the cavity. The probe contains all necessary optical components in a space-efficient arrangement, with light sources and cameras positioned to maximize the field of view within the constrained probe geometry. This nesting approach improves accessibility to restricted areas while keeping the external probe structure relatively simple.
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 enables high-precision scanning of interior surfaces with reduced production costs and improved fit accuracy for devices like hearing aids, minimizing acoustic feedback and simplifying the production process by eliminating the need for impressions.
Implementation Method 1
at least one light source configured to create and project structured light
Implementation Method 2
recording a series of 2D images of the reflection of the pattern from the interior surface using said camera
Data Source
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AI summary
According to an embodiment, a scanner system is disclosed. The scanner system includes a handheld scanner configured to scan interior surfaces of a body cavity; and a software for visualizing the acquired scan. The handheld scanner comprises a motion sensor for providing translations and rotations for the three principal coordinate axes whereby the handheld scanner is configured to act as a remote for rotating and/or panning the visualized acquired scan.