Surface Shape Map Measurement Using Multi-Sensor Arrays
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Solution Overview
Problem
Existing methods for measuring surface shape maps are limited by their reliance on accurate linear motion, which is often impractical, and struggle to achieve fine spatial resolution and accurate thickness measurements, especially for non-flat objects like logs, due to limitations in sensor arrangement and data handling.
Innovation Solution
The method employs multiple sensors arranged in geometric configurations that allow simultaneous measurement and data combination to separate surface shape features from relative motion effects, enabling the creation of surface shape maps independent of translation, pitch, and roll, with efficient mathematical procedures for real-time data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to measure surface shape maps, then measurement coverage and resolution are improved, but device complexity and computational burden increase
Solution Approach 1:
The measurement system is divided into multiple sensors arranged in specific geometric configurations (e.g., two lines intersecting at right angles). Each sensor measures distance to the object surface independently, and the data is segmented by spatial location. This segmentation allows complex surface maps to be constructed from simpler individual measurements, reducing the computational burden while maintaining precision.
Solution Approach 2:
The patent transitions from one-dimensional line measurements to two-dimensional surface maps by adding a spatial dimension. Multiple sensors arranged in geometric patterns enable simultaneous measurement of surface height profiles along different lines, creating a comprehensive surface map that captures both longitudinal and transverse variations without requiring complex sequential measurements.
2Ease of operation
If sensors are arranged in equally spaced parallel lines, then measurement regularity is improved, but spatial resolution and ability to measure non-flat objects deteriorate
Solution Approach 1:
Instead of using equally spaced parallel lines, the patent employs asymmetric geometric arrangements where two lines of sensors intersect at right angles. This asymmetric configuration allows the system to measure surface features in multiple directions simultaneously, improving spatial resolution and enabling accurate measurement of non-flat objects like logs while maintaining regular measurement intervals.
3Area of stationary object
If sequential measurements are made at small intervals, then measurement coverage is improved, but measurement time and computational burden increase
Solution Approach 1:
The patent merges multiple measurement functions into a single simultaneous operation. By arranging sensors in geometric configurations that can measure surface height profiles along multiple lines at the same time, the system covers larger surface areas without increasing measurement time. The combined data from all sensors are processed together to create comprehensive surface maps efficiently.
4Device complexity
If point sensors are used, then measurement simplicity is improved, but surface map generation and thickness measurement capability deteriorate
Solution Approach 1:
The patent extends point sensor measurements to line sensor measurements by adding a spatial dimension. Line sensors measure surface height profiles at multiple points along a line simultaneously, enabling the generation of comprehensive surface maps and accurate thickness measurements. This dimensional extension maintains measurement simplicity while significantly improving capability.
Data Source
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AI summary
A plurality of distance sensors are used to measure the surface shape map of objects in the presence of relative motions between the object and sensor in the measurement directions of the sensors. The method involves making multiple sequential measurements from a group of sensors while the object moves longitudinally relative to the sensors. The central idea of the invention is the observation that surface shape features appear in delayed sequence as the observed surface moves longitudinally relative to the sensor array, while any relative motions in the measurement directions appear simultaneously at all sensors. Mathematical procedures are used to identify the relative motions from within the measurements. These motions are then subtracted from the sensor reading to determine the surface shape map of the measured object. The invention can be applied to many different measurement types, including surface shape measurement of one- or multiple-sided generally flat objects, and surface shape measurement of more general three-dimensional objects.