Sensor Device Alignment Using IMU and LED Feedback
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Solution Overview
Problem
Laser scanners face challenges in precise alignment, particularly in determining angular orientations below 1°, due to the lack of suitable flat surfaces for alignment tools like spirit levels, and existing solutions are not intuitive for adjusting multiple angles in space.
Innovation Solution
A sensor device with an integrated IMU (Inertial Measurement Unit) as an electronic spirit level measures orientation relative to the gravitational field, using a simple display of multicolored LEDs to indicate correct or incorrect alignment, allowing for intuitive correction of the sensor's orientation without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a spirit level is used for alignment, then alignment can be performed with simple tools, but angular accuracy below 1° cannot be achieved due to lack of suitable flat surfaces
Solution Approach 1:
The patent replaces the mechanical spirit level system with an electronic orientation sensor (accelerometer-based) that electronically measures orientation relative to the gravitational field. This substitution enables high-precision angular measurement (better than 1°) without requiring flat physical surfaces, while maintaining ease of operation through electronic evaluation and display of alignment status.
2Measurement precision
If an electronic spirit level is used, then alignment precision can be improved, but the display is not intuitive for adjusting multiple angles in space
Solution Approach 1:
The patent implements a feedback system where the electronic orientation sensor continuously monitors the sensor device's orientation, and the control unit provides real-time feedback through a display device (such as an LED ring) that visually indicates alignment status. The display shows whether the device is properly aligned or indicates the direction and magnitude of misalignment, making it intuitive for users to adjust multiple angles in space without requiring interpretation of complex numerical data.
3Loss of information
If a position sensor is integrated into the laser scanner, then alignment information can be obtained, but the sensor is not calibrated ex works and no relationship exists between the position sensor orientation and the laser scanner orientation
Solution Approach 1:
The patent performs preliminary calibration action during the alignment process itself. The control unit determines the orientation of the sensor device using the electronic orientation sensor and compares it with the target orientation to calculate alignment deviation. This preliminary determination of the relationship between the position sensor and laser scanner orientation eliminates the need for separate factory calibration, as the calibration is automatically established during the first alignment operation.
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
Simplifies on-site alignment of laser scanners by providing immediate visual feedback on alignment status, enabling untrained personnel to correct orientations effectively and ensuring precise alignment without additional measurement tools.
Implementation Method 1
A position sensor, which is embodied, for example, as an IMU (Intertial Measurement Unit) and functions as a type of electronic spirit level, measures its orientation with respect to the gravitational field.
Data Source
Figure 1
Figure 2a~3b
Figure 4a~4b
AI summary
A sensor device (10) is described, comprising a housing (48a-b), a position sensor (44) for determining an orientation, a display device (46a-d) for displaying orientation information, and a control and evaluation unit (40) configured to determine the orientation of the sensor device (10) using the position sensor (44), to compare it with a target orientation, and to display the comparison result by means of the display device (46a-d). The display device (46a-d) has at least three light sources (46a-d) distributed across the housing (48a-b), each light source (46a-d) being capable of assuming at least one first display state for correct orientation and a second display state for incorrect orientation. The control and evaluation unit (40) is configured to display the comparison result by means of display states of the light sources (46a-d).