Strain Gauge Jig Alignment for Thermally Stable 3D Displays
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Solution Overview
Problem
Existing 3D light field displays experience diminished video quality due to thermally induced camera position variations, which cause geometric distortion and flickering or blurred images, as they lack the precision and thermally stable geometry needed for high-quality 3D video communication.
Innovation Solution
A system and method for precise installation of strain gauges on flexures using a customized jig and fixture, which includes a rigid back plate with alignment structures and translational motion guides, ensuring accurate placement of sensors to within +/- 0.2 mm, thereby maintaining camera positions and reducing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are installed manually on large format displays, then installation flexibility is maintained, but positioning precision deteriorates (cannot achieve +/- 0.2 mm accuracy)
Solution Approach 1:
A fixture serves as an intermediary device between the sensor and the large format display. The fixture includes a shelf with alignment structures that interface with corresponding features on the display, enabling precise sensor positioning without requiring direct manual installation on the display surface itself.
Solution Approach 2:
The fixture is prepared in advance with pre-machined alignment structures, slots, and holes that encode the precise positioning information. This preliminary preparation of the fixture allows sensors to be accurately positioned when installed, achieving +/- 0.2 mm precision without requiring complex real-time adjustment procedures.
2Reliability
If camera positions are not precisely maintained, then device complexity is reduced, but image quality deteriorates (geometric distortion and flickering occur)
Solution Approach 1:
Strain gauges are installed on flexures that are integrated into the camera mounting structure. These strain gauges provide real-time feedback on thermal expansion and contraction of the display and mounting structure, allowing the system to detect and compensate for position variations that would otherwise cause geometric distortion and flickering.
Solution Approach 2:
The system explicitly accounts for thermal expansion effects by installing strain gauges on flexures that experience thermal deformation. The feedback from these gauges allows the system to compensate for thermal-induced camera position variations, maintaining image quality despite temperature changes during operation.
3Manufacturing precision
If alignment structures are added to the fixture, then sensor placement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The alignment functionality is segmented into separate, modular components: alignment structures on the shelf, corresponding alignment features on the film, and slot-guide mechanisms. This segmentation allows each component to be manufactured independently using standard machining operations, reducing overall manufacturing complexity while maintaining precision.
Solution Approach 2:
The alignment system uses dimensional reduction by providing alignment constraints in specific dimensions through slots and guide structures. Rather than requiring precise alignment in all three dimensions simultaneously, the fixture provides guided movement in controlled dimensions, simplifying the manufacturing requirements while achieving the needed +/- 0.2 mm precision.
Data Source
AI summary
Systems and devices are disclosed for improving image quality in a video communication system. The video communication system can be a 3D teleconferencing system that includes a large format display. Improvements can be realized through the use of a jig that provides for precise installation of sensors onto surfaces of a flexure device that mounts to the back side of the display. The sensors can include structural sensors such as strain gauges that can provide feedback regarding distortion of the display that can disturb camera locations. The devices, systems, and methods described may apply generally to the installation of sensors in high volume manufacturing.