Reflective Calibration Wall for Laser Projector Alignment
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Solution Overview
Problem
Current laser projector calibration methods rely on visual estimation, which is time-consuming and inefficient, reducing the production and assembly efficiency in manufacturing processes.
Innovation Solution
A reflective calibration wall system with a structural frame, positioning stages, and movable reflective targets that enable quantitative analysis and precise alignment of laser beams, allowing for quick correction of out-of-tolerance projectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If visual estimation is used for calibration, then the calibration process can be performed with simple equipment, but the calibration time increases and productivity decreases
Solution Approach 1:
The patent replaces the mechanical/visual estimation method with an optical measurement system. A camera captures images of the laser beams, and image processing algorithms automatically calculate the beam positions and orientations, eliminating the need for manual visual estimation and significantly reducing calibration time while maintaining high measurement precision.
Solution Approach 2:
The patent introduces an intermediary measurement system consisting of a camera and image processing software. This intermediary captures the laser beam positions and provides quantitative data for calibration, serving as a mediator between the laser projection system and the calibration process, thereby enabling automated and precise calibration without direct human visual estimation.
2Ease of operation
If visual estimation is used for calibration, then the calibration process is simple to perform, but the measurement precision is insufficient for critical manufacturing applications
Solution Approach 1:
The patent replaces manual visual estimation with an automated optical measurement system. The camera captures laser beam positions with high precision, and image processing algorithms automatically calculate the beam orientations and offsets, providing measurement precision sufficient for critical manufacturing applications while maintaining ease of operation through automated processing.
Solution Approach 2:
The patent implements a feedback mechanism where the camera captures the actual laser beam positions, the system calculates the deviations from the expected positions, and this information is fed back to adjust the calibration. This closed-loop feedback ensures high measurement precision by continuously monitoring and correcting the laser beam orientations based on actual measured positions.
3Device complexity
If manual calibration methods are used, then the equipment required is minimal, but the time consumed for calibration increases production costs
Solution Approach 1:
The patent replaces manual calibration operations with an automated optical measurement and processing system. The camera-based system automatically captures laser beam positions, processes the images to calculate orientations and offsets, and provides calibration data without requiring manual intervention, thereby significantly reducing calibration downtime while the equipment complexity remains manageable through the use of standard optical components.
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
The system enhances the accuracy and efficiency of laser projector calibration, reducing downtime and costs associated with calibration and testing, while improving the productivity of manufacturing processes.
Implementation Method 1
Each of the positioning stages is provided with a movable reflective target that is configured to reflect a corresponding laser beam
Data Source
AI summary
Apparatus and methods for calibrating a laser projection system that is used for marking and guidance of components during manufacturing are disclosed. The apparatus includes a structural frame. One or more positioning stages are coupled to the structural frame. Each of the positioning stages is provided with a movable reflective target that is configured to reflect a corresponding laser beam.