Patent Application
20200393544
The present disclosure relates to an illuminated aperture emitter for three-dimensional position measurement.
Constellations of light emitters are often used by automated and manual optical measurement instruments to measure movement of a rigid body in three-dimensional space—i.e., the six degrees of freedom (“6DoF”). Constellations include signal data for a variety of single-point light emitters that are stably mounted on a rigid body and subsequently viewed by an optical receiving element that collects the emitted light onto imaging sensors. Once collected, the signal data is processed by a computing element to derive the six degree of freedom position of the rigid body in free space.
In such instances, to provide spatial accuracy the three-dimensional position of each emitter must be known relative to each other, as well as with regard to the rigid body onto which the emitters are mounted. The three-dimensional positions of the light emitters are generally measured during manufacturing of measurement instrument using a calibration process. For example, in various instances, such calibration processes may utilize various optical means to measure the spatial position of the emitters, and in various other instances, various mechanical means—such as a ruby-tipped probe deployed on a Coordinate Measuring Machine (“CMM”)—may be used. The various mechanical means provide greater accuracy than the various optical means; however, because of the small and delicate nature of the emitters, it is often difficult to mechanically measure the three-dimensional position of the light emitters.
Various other factors may also affect the precise accuracy of such calibration processes and/or measurement instrument. For example, in certain instances, the emitters include bare light emitting diode (“LED”) dies and anode wires. In such instances, when portions of the light emitters are environmentally exposed, airborne debris commonly found in manufacturing plants may fall onto the dies and/or wires so as to skew the calibration method and/or permanently or temporarily render the measurement instrument non-functional. In the instance of coherent fiber bundles, discrepancies in centering the LED under the fiber bundle are common.
Accordingly, it would be desirable to develop devices and methods that improve the ruggedness and accuracy of three-dimensional position measurements.
This section provides background information related to the present disclosure which is not necessarily prior art.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
In various aspects, the present disclosure provides a system for measuring a position of a rigid object. The system includes one or more light emitters disposed on one or more surfaces of the rigid object and an optical measurement instrument configured to receive light from the one or more light emitters and further configured to determine the position of the rigid object using the received light. Each light emitter includes a light-emitting device having a light-emitting surface, a transparent plate disposed on the light-emitting surface, and an opaque film disposed between the light-emitting surface and the transparent plate. The opaque film includes an aperture that is aligned with the light-emitting surface.
In one aspect, the transparent plate may define an edge of the light emitter and one or more positions along the edge of the light emitter may be measured using a mechanical coordinate-measuring machine (“CMM”).
In one aspect, the optical measurement instrument may be further configured to receive the one or more edge measurements and to use the one or more edge measurements to determine the position of the rigid object.
In one aspect, the aperture may have a first longest dimension that is smaller than a second longest dimension of the light-emitting surface, such that edges of the light-emitting surface are not visible through the aperture over a large angle.
In one aspect, the aperture may have one of a circular shape, an elliptical shape, and a shape of an even-sided polygon. The light-emitting surface may have one of a circular shape, an elliptical shape, and a shape of an even-sided polygon.
In one aspect, a first longest dimension of the aperture may be greater than 100:1 by ratio of a thickness of the opaque film, and a first thickness of the transparent plate may be greater than a second thickness of the opaque film.
In one aspect, the transparent plate may be a glass plate comprising fused silica, sapphire, soda lime glass, boro-silicate, or a combination thereof. The opaque film may be a film comprising chrome, silver, aluminum, carbon, dielectric, or a combination thereof.
In one aspect, the opaque film may cover less than an entire surface area of a first surface of the transparent plate, and exposed areas of the first surface of the transparent plate may be bonded to the rigid object.
In one aspect, the exposed areas of the first surface of the transparent plate may be bonded to the rigid object using ultraviolet curing.
In one aspect, the opaque film may be disposed on a first surface of the transparent plate using a vapor deposition process and the aperture may be formed in the opaque film using an etching process. The transparent plate may be fabricated using a semiconductor fabrication technique selected from laser dicing and saw dicing.
In various other aspects, the present disclosure provides a system of measuring a position of a rigid object. The system includes one or more light emitters disposed on one or more surfaces of the rigid object and an optical measurement. Each light includes a light-emitting device having a light-emitting surface, and a transparent plate disposed on the light-emitting surface. An opaque film having an aperture defined therein coats a first surface of the transparent plate, and the transparent plate defines an edge of the light emitter. The optical measurement instrument is configured to receive light from the one or more light emitters and one or more edge measurements for each light emitter. The optical measurement instrument is further configured to determine the position of the rigid object using the received light and the one or more edge measurements.
In one aspect, the one or more edge measurements may be measured using a mechanical coordinate-measuring machine (“CMM”).
In one aspect, the aperture may be registered to the edge of the light emitter and may have a first longest dimension that is smaller than a second longest dimension of the light-emitting surface, such that edges of the light-emitting surface are not visible through the aperture over a large angle. The first longest dimension of the aperture may be greater than 100:1 by ratio of a thickness of the opaque film, and a first thickness of the transparent plate may be greater than a second thickness of the opaque film.
In one aspect, the transparent plate may be a glass plate comprising fused silica, sapphire, soda lime glass, boro-silicate, or a combination thereof. The opaque film may be a film comprising chrome, silver, aluminum, carbon, dielectric, or a combination thereof.
In one aspect, the opaque film may cover less than an entire surface area of the first surface of the transparent plate, and exposed areas of the first surface of the transparent plate may be bonded to the rigid object.
In yet another aspect, the present disclosure provides a method for measuring a position of a rigid object. The rigid object may include one or more light emitters disposed on one or more surfaces thereof. The method includes measuring one or more positions along an edge of each light emitter. Each light emitter includes a light-emitting device having a light-emitting surface, and a transparent plate disposed on the light-emitting surface. The transparent plate defines the edge of the light emitter, and an opaque film having an aperture defined therein coats a first surface of the transparent plate. The method further includes using the edge measurements to determine a three-dimensional position for each aperture and receiving light from the one or more light emitters. The light received from the one or more light emitters and the three-dimensional position of each aperture are used to determine the position of the rigid object.
In one aspect, the one or more positions along the edge of the light emitter may be measured using a mechanical coordinate-measuring machine.
In one aspect, the opaque film may be disposed on the first surface of the transparent plate using a vapor deposition process and the aperture may be formed in the opaque film using an etching process. The transparent plate may be fabricated using a semiconductor fabrication technique selected from laser dicing and saw dicing.
In one aspect, the aperture may have a first longest dimension that is smaller than a second longest dimension of the light-emitting surface, such that edges of the light-emitting surface are not visible through the aperture over a large angle. The first longest dimension of the aperture may be greater than 100:1 by ratio of a thickness of the opaque film and a first thickness of the transparent plate is greater than a second thickness of the opaque film.
In one aspect, the transparent plate may be a glass plate comprising fused silica, sapphire, soda lime glass, boro-silicate, or a combination there. The opaque film may be a film comprising chrome, silver, aluminum, carbon, dielectric, or a combination thereof. The opaque film may cover less than an entire surface area of the first surface of the transparent plate, and exposed areas of the first surface of the transparent plate may be bonded to the rigid object.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
With reference to
The aperture 120 may be formed at any point along the opaque film 114, so long as the aperture 120 is formed or disposed at a known location relative to the edges 118 of the transparent plate 110. For example, as seen in the illustrated embodiment, the aperture 120 may be formed at a center point of the film 114 and disposed centrally on the transparent plate 110. The aperture 120 may take a variety of shapes. For example, as seen in the illustrated embodiment, the aperture 120 may have a circular shape. In various other aspects, the aperture 120 may have an elliptical shape or the shape of an even-sided polygon, such as a square.
In various aspects, the transparent plate 110 may be any durable transparent material and the opaque film 114 may be any opaque material. For example, in various instances, the transparent plate 110 may be a glass plate comprising fused silica, sapphire, soda lime glass, boro-silicate, or combinations thereof; and the transparent film 114 may comprise one or more opaque materials, such as chrome, silver, aluminum, carbon, dielectric, or combinations thereof. In various embodiments, the transparent plate 110 may have a first thickness ranging from greater than or equal to about 1 mm to less than or equal to about 3 mm. As best illustrated in
The plate 110 and film 114 are fabricated using any accurate fabrication method. As best illustrated in
As illustrated in
Like the aperture 120, the light-emitting surface 146 may take a variety of shapes. For example, as seen illustrated, the light-emitting surface 146 may have a square shape. In various other aspects, the light-emitting surface 146 may have a circular shape, an elliptical shape, or the shape of another even-sided polygon. The longest length or diameter of the aperture 120 (i.e., the first longest dimension) is smaller than the longest length or diameter of the light-emitting surface 146 (i.e., the second longest dimension). The smaller first diameter of the aperture 120 may optimize the intensity and uniformity of light emitted by the light-emitting diode 144—for example, such that edges of the light-emitting surface 146 are not visible through the aperture 120 over large angles (e.g., ±60 degrees).
The light emitter 100 may be coupled to a power source 150 via a corresponding module plug 152 and jack 154. The jack or receiver 154 is coupled to the light-emitting device 142 and the plug 152 is coupled to the power source 150. In certain aspects, as illustrated in
After the opaque film is disposed on the first surface of the transparent plate, an aperture is formed in the opaque film at 186 using, for example, etching or liftoff processes; and at 188, the method includes accurately cutting the transparent plate using, for example, a semiconductor fabricating technique. The opaque member including the transparent plate and the etched opaque film—i.e., the aperture—is disposed on a light-emitting device. In particular, at 190, the aperture formed in the opaque film is aligned with a light-emitting surface of the light-emitting device and, at 192, the opaque member is attached to the light-emitting device.
In various aspects, the one or more positions along the edge 118 and/or exposed surface 119 of the plate 110 may be measured and the measurements may be used to determine the three-dimensional position of each aperture 120. For example, in certain variations, two or more positions along the edge 118 of the plate 110, and in certain instances, optionally three or more positions along the edge 118 of the transparent plate 110, may be measured. Further, two or more positions along the exposed surface 119, and in certain instances, optionally three or more positions along the exposed surface 119 of the transparent plate 110, may be measured, such that six or more positions along the transparent plate 110 are measured. The six or more positions measured along the transparent plate 110 are used to determine the three-dimensional position of the aperture 120 of the particular light emitter 100.
In various aspects, optical means may be used to measure the one or more positions. In various other instances, one or more mechanical methods may be used to measure the one or more positions. For example, as illustrated in
As noted, the measurements of the one or more positions along the edge 118 of the precisely defined transparent plate 110 and the measurements of the one or more exposed surface 119 of the precisely defined transparent plate 110 may be used to determine the three-dimensional position of the plate 110. For example, as illustrated in
The receiving element 500 may use the three-dimensional position of the transparent plate 110 to determine the three-dimensional position of the aperture 120. For example, the meticulous fabrication of the light emitter 100, including the positioning of the aperture 120 and subsequent alignment of the aperture 120 and light-emitting surface 146, may allow the position of the aperture 120 to be inferred using known variables once the edges 118 of the transparent plate 110 are defined. Using the inferred position of the aperture 120 and light emitted 520 by the light emitter 100 and received by the receiving device 500, the receiving device 500 may determine the position of the rigid object 200. For example, the one or more light emitters 100 are registered to a specific position on the rigid body 200. Therefore, as with the fabrication of each light emitter 100, the position of the rigid body 200 may be determined using known variables.
At 612, the various edge measurements are used to determine a three-dimensional position of each light emitter, and at 616, the three-dimensional position of the light emitters are used to determine the three-dimensional position of each aperture. For example, using known variables from the precise fabrication of the light emitters—in particular, in cutting the transparent plate and formation of the aperture—the position of each aperture can be inferred when the three-dimensional position of the light emitter is known.
The three-dimensional position of each aperture, together with light received from the various light emitters, are used to determine the position of the rigid object at 620. For example, using known variables from the precise placement of the light emitters on the rigid body, the position of the rigid object can be determined.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
