Sensor Alignment via Passive Contrast Pattern Scanning
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Solution Overview
Problem
Existing area distance sensors are structurally complex and expensive due to numerous active optical and electronic components, limiting their accuracy and resolution during alignment.
Innovation Solution
A passive alignment element with a contrast pattern is used, which is scanned by the sensor's light beams to determine its distance and amplitude curve, allowing for precise alignment of the scanning plane without active components, and can be integrated as a simple object or film on the floor or wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If active alignment units with multiple active components are used, then alignment information can be provided, but the structural complexity and cost increase significantly
Solution Approach 1:
The patent uses a contrast pattern that is optically captured by the sensor instead of physical active alignment components. The contrast pattern serves as an optical copy or representation of alignment information, allowing the sensor to determine its orientation and position without requiring active alignment units with multiple components.
Solution Approach 2:
The invention extracts only the necessary alignment information function from the complex active alignment unit. Instead of using multiple active components to provide alignment information, the patent extracts this function by using a simple contrast pattern that can be captured and evaluated by the sensor's existing imaging components.
2Ease of operation
If discrete photodiodes are used in the alignment unit, then alignment detection is possible, but the resolution and accuracy are limited
Solution Approach 1:
The contrast pattern creates an optical representation that can be captured with high resolution by the sensor's image recorder. This optical copy allows for precise determination of the sensor's alignment by analyzing the position and characteristics of the captured pattern, achieving higher accuracy than discrete photodiodes.
Solution Approach 2:
The patent transitions from one-dimensional discrete photodiode detection to two-dimensional continuous image capture. The contrast pattern is captured as a 2D image, allowing for more precise measurement of alignment by analyzing the spatial distribution of light across the image sensor, thereby increasing measurement precision.
3Ease of operation
If active optical and electronic components are used in the alignment unit, then alignment information can be displayed, but manufacturing cost increases
Solution Approach 1:
The alignment information is provided through a printed or projected contrast pattern rather than active electronic display components. This optical copy approach eliminates the need for expensive active alignment units with multiple electronic components, significantly reducing manufacturing costs while maintaining alignment information display capability.
Solution Approach 2:
The sensor system uses its own imaging components to capture and evaluate the contrast pattern for alignment determination. The system serves itself by utilizing existing sensor components rather than requiring separate active alignment and display units, thereby reducing manufacturing costs.
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 solution enables cost-effective and accurate alignment of the area distance sensor with reduced complexity, improving its precision and ease of integration while maintaining a fail-safe structure for safety applications.
Implementation Method 1
a transmitter (4) emitting light beams (3) and a receiver (5) receiving light beams (3) reflected back from an object
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5
AI summary
The invention relates to a sensor arrangement (100) comprising an area distance sensor (1), a light beam emitting transmitter (4), and a light beam receiving receiver (5). The light beams (3) are guided periodically in a scanning plane. Distances to objects (7) are determined by an evaluation unit based on the received signals from the receiver (5). At least one alignment element (16) is provided, which is arranged at an angle to the scanning plane so that it protrudes vertically above the scanning plane. The alignment element (16) has a contrast pattern that changes unambiguously along its height. The evaluation unit uses the received signals from the receiver (5) to determine the distance of the alignment element (16) and the amplitude profile of the received signals during scanning of the contrast pattern with the light beams (3) as a measure of the orientation of the scanning plane.