Projector Sensor Holder Integration for Positional Accuracy
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Solution Overview
Problem
In projectors with sensors for image adjustment, the accumulation of dimensional tolerances and part deformation due to heat and aging leads to a decrease in the relative positional accuracy between the sensor and the projection system, resulting in inaccurate image adjustments.
Innovation Solution
A projector design where the sensor holder is directly connected to the lens barrel holder, reducing the number of intermediate components and using metal materials with lower coefficients of linear expansion to minimize positional shifts and deformations, ensuring precise image correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple intermediate parts (holding member and sensor holding member) are used to attach the projection system and sensor to the enclosure, then the ease of assembly and manufacturing flexibility are improved, but the dimensional tolerance accumulation increases and the relative positional accuracy between the sensor and projection system deteriorates
Solution Approach 1:
The patent merges the holding member and sensor holding member into a single integrated structure. The sensor is directly mounted on the holding member that also supports the projection system, eliminating the separate sensor holding member. This integration reduces the number of interfaces and dimensional tolerance accumulation points, thereby improving the relative positional accuracy between the sensor and projection system while maintaining ease of assembly through the unified structure.
2Ease of repair
If multiple separate holding members are used, then the ease of repair and component replacement are improved, but the deformation accumulation due to heat and aging increases, worsening the relative positional accuracy
Solution Approach 1:
By integrating the holding member and sensor holding member into one unified component, the patent reduces the total number of parts subject to thermal and aging deformation. The single integrated structure minimizes the cumulative deformation effects that would occur across multiple separate components, thereby maintaining better relative positional accuracy over time while still allowing for modular replacement of the entire assembly if needed.
3Manufacturing precision
If a simple holding structure with fewer components is used, then the deformation accumulation due to heat and aging is reduced, improving the relative positional accuracy, but the ease of manufacture and assembly flexibility deteriorate
Solution Approach 1:
The patent achieves a balance by integrating the holding and sensor-mounting functions into a single structure. This merged design reduces the number of components and interfaces, thereby minimizing deformation accumulation and improving relative positional accuracy. Simultaneously, the integrated structure is designed to be manufacturable using standard processes, maintaining ease of production and assembly flexibility without requiring excessive 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 configuration maintains high relative positional accuracy between the sensor and projection system, enabling precise correction of trapezoidal distortion and reducing the impact of thermal and aging-related deformations, thus ensuring accurate image projection.
Implementation Method 1
Dimensional tolerances of the large number of parts therefore accumulate between the sensor and the projection system, resulting in a decrease in the relative positional accuracy of the sensor and the projection system. Further, when deformation of each of the parts due to heat and aging accumulates
Data Source
AI summary
A projector includes a light source, a light modulator that modulates light outputted from the light source, a projection system that projects the light modulated by the light modulator, an image sensor that acquires information on an image projected by the projection system, an enclosure that accommodates the light source, the light modulator, and the image sensor, and a sensor holder that holds the image sensor. The projection system includes a lens barrel which accommodates a lens and through which the light modulated by the light modulator passes. The lens barrel is held by the enclosure via a lens barrel holder. The sensor holder is held by the lens barrel holder.