3D Tracked Imaging Device for Precise Surface Reproduction
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Solution Overview
Problem
Current methods for reproducing images on complex surfaces are time-consuming, lack accuracy, and require multiple equipment setups, especially when projecting onto large or contoured surfaces without physical reference points, leading to potential errors and production delays.
Innovation Solution
A system that uses a movable imaging device tracked by a three-dimensional position tracker, correlated with a computer model, to ensure precise placement of images on surfaces, employing a controller to verify and adjust the output device's position before marking, utilizing a common coordinate system for accurate reproduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser projectors are used to project images onto contoured surfaces, then image reproduction is enabled, but positioning accuracy deteriorates requiring multiple projector heads and set-ups
Solution Approach 1:
The patent introduces a tracking system as an intermediary between the laser projector and the contoured surface. The tracker monitors the three-dimensional position of the projector head in real-time, providing feedback data that enables automatic adjustment of projection parameters. This mediator resolves the positioning accuracy issue without requiring multiple projector heads, as the single projector can be precisely controlled through tracker feedback.
Solution Approach 2:
The system implements a feedback mechanism where the tracker continuously monitors the projector head's position and feeds this information back to the control system. The control system then automatically adjusts the projection parameters based on the tracked position data, ensuring accurate image reproduction on contoured surfaces. This closed-loop feedback eliminates the need for manual repositioning and multiple set-ups.
2Ease of operation
If the projector head is placed close to the object to overcome physical obstructions, then focal length limitations are reduced, but the ability to project over the entire surface deteriorates
Solution Approach 1:
The system transitions from a static projector setup to a dynamic one where the projector head can be precisely positioned and adjusted in three-dimensional space. The tracking system enables real-time monitoring and adjustment of the projector's position, allowing it to adapt to various distances and angles while maintaining accurate projection coverage across the entire contoured surface.
3Manufacturing precision
If manual positioning methods are used for marking devices, then setup simplicity is maintained, but marking precision deteriorates leading to scrap and production delays
Solution Approach 1:
The system implements self-service through automatic verification and control. The tracker automatically verifies the projector head's position, and the control system automatically adjusts parameters and triggers the marking process. This eliminates manual positioning and verification steps, ensuring high marking precision while reducing production delays through automation.
Solution Approach 2:
The system performs preliminary verification of the projector head's position before the actual marking occurs. The tracker confirms proper positioning in advance, and the control system validates parameters before triggering the marking device. This preliminary action prevents incorrect markings that would lead to scrap and rework, thereby reducing production delays.
Data Source
AI summary
Systems and methods of reproducing images onto surfaces are disclosed. In one embodiment, the system includes an image file that digitally produces a planar surface normal to a surface of a master model. The planar surfaces are referenced to a coordinate system of the master model through a series of points. A tracker surfacing system, comprising a tracking instrument, generates and emits a signal as the tracking instrument crosses the planar surface. An output device is actuated by the tracking device as it crosses the planar surface, reproducing the series of points as an image onto a surface, including a flat, curved or compound surface. Both the spatial position and orientation of the output device are detected and adjustments are made so that the image is precisely applied to intended locations on the surface being imaged.