Targetless Laser Projection System with External Metrology
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Solution Overview
Problem
Conventional laser projection systems require laser targets on the surface, which can interfere with operations, are impractical for large surfaces, and suffer from image drift due to environmental variations, limiting their application and accuracy.
Innovation Solution
A 'targetless' laser projection system that uses external metrology devices to determine the position and orientation of both the target surface and the laser projector, eliminating the need for surface-mounted targets and allowing for accurate projection without requiring targets within the projector's field of view, and correcting for image drift by scanning internal targets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser targets are mounted on the target surface, then the position and orientation of the laser projector can be determined, but the targets interfere with further operations and are impractical for large surfaces
Solution Approach 1:
The patent extracts the laser targets from the target surface and relocates them to a separate reference structure (frame or truss). This allows the targets to remain accessible for measurement purposes while eliminating their interference with operations on the target surface itself. The reference structure serves as an independent carrier for the targets, decoupling the measurement reference from the work surface.
Solution Approach 2:
The patent introduces a reference structure (frame or truss) as an intermediary element between the laser projector and the target surface. This intermediary carries the laser targets and provides a stable reference framework, allowing position determination without requiring targets to be mounted directly on the target surface, thus resolving the conflict between measurement accuracy and operational accessibility.
2Area of stationary object
If laser targets are placed on large surfaces, then coverage area increases, but the required projection area becomes too large to allow placement of targets within the field of view
Solution Approach 1:
The patent transitions from a two-dimensional arrangement where targets must lie within the projector's field of view on the target surface, to a three-dimensional configuration where the reference structure elevates targets above the target surface. This vertical separation allows the projector to maintain a fixed, limited field of view while still determining positions across large horizontal areas through spatial triangulation and coordinate transformation.
3Ease of operation
If manual calibration and positioning are used, then the system can be set up, but the process is time-consuming and requires careful control to ensure adequate position reference
Solution Approach 1:
The patent implements preliminary action by pre-establishing a reference structure with laser targets at known, predetermined locations before the actual laser projection work begins. The reference structure is constructed with precise, pre-calculated coordinates, so when the laser projector is set up, the positions of all targets are already known in advance. This eliminates the need for time-consuming manual calibration and positioning during the actual operation, as the coordinate system is pre-defined and ready for use.
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
Enables precise and flexible laser template projection on large surfaces without surface-mounted targets, improving accuracy and adaptability, and correcting for image drift without the need for manual calibration or surface-mounted targets.
Implementation Method 1
a laser projector or a plurality of laser projectors mounted above the work surface
Implementation Method 2
the reflected light from the laser targets to the sensor of the laser projector determines the precise projection angle
Data Source
AI summary
A laser imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift. Kinematic supports for the metrology receivers are disclosed as well as an independent laser tracker.