3D Structured Light Scanning for Vehicle Body Repair
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Solution Overview
Problem
Current methods for repairing and aligning automobile upper body damage are inefficient, costly, and prone to errors due to the lack of comprehensive data sets for upper body specifications, including sensor placements and contoured surfaces, which are critical for modern automotive safety systems.
Innovation Solution
A 3D structured light scanning system and method that captures detailed measurements of upper body components, sensors, and contoured surfaces, creating a holistic data set for accurate alignment and repair, even in the absence of existing databases, by using symmetrical measuring and in-process scanning during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional single-point laser and tape measure methods are used for measuring upper body configurations, then the measurement process is simple and quick, but the measurement precision is insufficient for curved surfaces and contoured panels
Solution Approach 1:
The patent replaces traditional mechanical measurement tools (tape measures, single-point lasers) with a 3D structured light scanning system that uses optical fields to capture complete surface geometry. The structured light scanner projects patterned light onto the vehicle surface and captures deformation patterns to calculate three-dimensional coordinates of multiple points simultaneously, enabling accurate measurement of curved surfaces without complex manual procedures.
Solution Approach 2:
The patent transitions from one-dimensional point-to-point measurements to three-dimensional volumetric scanning. The structured light scanning system captures the complete spatial configuration of upper body components by measuring multiple points in three-dimensional space simultaneously, creating a comprehensive digital model that preserves surface curvature and spatial relationships that cannot be obtained with traditional linear measurement methods.
2Manufacturing precision
If comprehensive upper body data sets including sensor placements are collected, then the alignment accuracy of safety sensors is improved, but the data collection process becomes time consuming and complex
Solution Approach 1:
The patent performs upper body specification data collection during the vehicle manufacturing process before delivery to the customer. The structured light scanning system captures complete three-dimensional data of upper body components, sensor placements, and contoured surfaces as part of the assembly process, creating a permanent digital record that can be referenced throughout the vehicle's lifecycle without requiring repeated measurement visits.
Solution Approach 2:
The patent establishes continuous availability of upper body specification data by collecting it during manufacturing and storing it in a database. This eliminates the need for repeated measurement visits during repair or maintenance operations, as the complete three-dimensional data set remains continuously accessible to repair technicians throughout the vehicle's service life.
3Loss of information
If traditional stand-alone OEM drawings are used for measuring openings, then the data is easy to access, but the spatial relationship between different openings and components cannot be established
Solution Approach 1:
The patent merges multiple separate measurement data sets into a single integrated three-dimensional model. The structured light scanning system simultaneously captures the geometry of multiple upper body components, openings, and sensor placements, creating a unified digital representation that preserves all spatial relationships between elements. This integrated model combines information that would otherwise be scattered across separate drawings and measurements.
Solution Approach 2:
The patent creates a universal three-dimensional data set that serves multiple functions simultaneously. The same scanned data can be used for measuring openings, locating sensors, determining component alignments, and guiding repairs across different vehicle systems. This multi-functional data resource eliminates the need for separate specialized measurement procedures for each component.
4Productivity
If manual measurement and alignment processes are performed, then the equipment requirements are minimal, but the repair process becomes expensive and time consuming
Solution Approach 1:
The patent creates a digital copy of the vehicle's upper body configuration through three-dimensional scanning. This digital model serves as a virtual template that repair technicians can reference to accurately reconstruct damaged components without physically measuring each dimension manually. The digital copy preserves all geometric features, surface contours, and spatial relationships, enabling rapid and accurate repair guidance.
Solution Approach 2:
The patent introduces a computer-based intermediary system that bridges the gap between the physical vehicle and the repair process. The three-dimensional scanning system captures the vehicle's current state and creates digital models that can be processed, analyzed, and used to generate repair instructions. This digital intermediary eliminates the need for manual measurement and calculation, automating the information extraction process and providing precise guidance for repairs.
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 approach enables precise and efficient repair processes, reduces human error, and provides a comprehensive data set for vehicle specifications, facilitating the alignment of safety sensors and other components, thus enhancing the accuracy and speed of vehicle repairs and production.
Implementation Method 1
A 3D structured light scanning system and method that captures detailed measurements of upper body components, sensors, and contoured surfaces
Data Source
AI summary
Systems and methods of repairing damage to the body structure of a vehicle based on a comparison of vehicle damage to vehicle specification data to indicate the magnitude and direction of vehicle damage to formulate a repair plan for review.