U.S. patent application number 14/747197 was filed with the patent office on 2016-12-29 for optical pattern projector.
The applicant listed for this patent is Hand Held Products, Inc.. Invention is credited to Alain Gillet, Bernard Puybras, Serge Thuries.
Application Number | 20160377414 14/747197 |
Document ID | / |
Family ID | 56117545 |
Filed Date | 2016-12-29 |
United States Patent
Application |
20160377414 |
Kind Code |
A1 |
Thuries; Serge ; et
al. |
December 29, 2016 |
OPTICAL PATTERN PROJECTOR
Abstract
An optical pattern projector used for projecting a
structured-light pattern onto an object for dimensioning is
presented. The optical pattern projector utilizes a laser array, a
lenslet array, a lens, and a diffractive optical element to create
a repeated pattern of projected dots. The pattern repetition is
based on the grid pattern of laser array. Each laser's collimated
beam, when projected through the lens, impinges on the diffractive
optical element from a slightly different direction. The
diffractive optical element creates a sub-patterns that continue
propagating along these different directions and combine on a
target to produce a repeating optical pattern.
Inventors: |
Thuries; Serge; (Saint Jean,
FR) ; Gillet; Alain; (Toulouse, FR) ; Puybras;
Bernard; (Saint Pierre De Lages, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hand Held Products, Inc. |
Fort Mill |
SC |
US |
|
|
Family ID: |
56117545 |
Appl. No.: |
14/747197 |
Filed: |
June 23, 2015 |
Current U.S.
Class: |
356/625 ;
359/558 |
Current CPC
Class: |
G01B 11/02 20130101;
G02B 27/0961 20130101; G02B 27/106 20130101; G02B 13/0005 20130101;
G02B 27/0944 20130101; G02B 27/20 20130101; G02B 3/0056 20130101;
H01S 5/423 20130101; G02B 27/4233 20130101; G01B 11/25 20130101;
G02B 27/1093 20130101 |
International
Class: |
G01B 11/25 20060101
G01B011/25; G02B 3/00 20060101 G02B003/00; G02B 13/00 20060101
G02B013/00; H01S 5/42 20060101 H01S005/42; G01B 11/02 20060101
G01B011/02; G02B 27/42 20060101 G02B027/42 |
Claims
1. An optical pattern projector, comprising: a laser array, having
a plurality of lasers equally spaced in a grid pattern and
configured to radiate light in the same direction; a lenslet array
having a plurality of lenslets arranged so that each lenslet is
aligned with a particular laser, the lenslet array positioned in
front of the laser array to focus the radiated light from the
lasers into a plurality of collimated laser beams; a lens
positioned in front of the lenslet array and sufficiently large to
receive all of the laser beams, the lens redirecting each laser
beam along a particular incident angle determined by the spatial
position of the particular laser beam in the grid pattern; and a
diffractive optical element (DOE) positioned in front of the lens
to receive all of the laser beams and, for each laser beam, to (i)
create a sub-pattern and (ii) project each laser beam's sub-pattern
towards a target along a particular angle determined by the
particular laser beam's incident angle, wherein the sub-patterns
from each laser beam combine on the target to form an optical
pattern.
2. The optical pattern projector according to claim 1, wherein the
laser array is an array of vertical cavity surface emitting lasers
(VCSELs).
3. The optical pattern projector according to claim 2, wherein the
laser array comprises more than 100 VCSELs.
4. The optical pattern projector according to claim 1, wherein the
lens is an f-theta lens.
5. The optical pattern projector according to claim 1, wherein the
sub-patterns from the laser beams are identical.
6. The optical pattern projector according to claim 1, wherein the
optical pattern comprises the sub-patterns arranged according to
the grid pattern.
7. The optical pattern generator according to claim 1, wherein the
sub-pattern comprises a non-uniform pattern of light spots.
8. The optical pattern generator according to claim 1, wherein the
sub-pattern comprises 3-15 light spots.
9. The optical pattern generator according to claim 1, wherein the
light radiated is infrared light.
10. The optical pattern projector according to claim 1, wherein the
lenslets comprise more than one optical element.
11. A structured-light dimensioning system, comprising: an optical
pattern projector for projecting a structured-light pattern onto an
object for dimensioning, wherein the optical pattern projector
comprises: a laser array, having a plurality of lasers equally
spaced in a grid pattern and configured to radiate light in the
same direction, a lenslet array having a plurality of lenslets
arranged so that each lenslet is aligned with a particular laser,
the lenslet array positioned in front of the laser array to focus
the radiated light from the lasers into a plurality of collimated
laser beams, a lens positioned in front of the lenslet array and
sufficiently large to receive all of the laser beams, the lens
redirecting each laser beam along a particular incident angle
determined by the spatial position of the particular laser beam in
the grid pattern, and a diffractive optical element (DOE)
positioned in front of the lens to receive all of the laser beams
and for each laser beam to (i) create a sub-pattern and (ii)
project each laser beam's sub-pattern towards the object along a
particular angle determined by the particular laser beam's incident
angle; a imaging subsystem for capturing images of the
structured-light pattern transmitted by the optical pattern
projector and reflected from the object; and a range mapping
subsystem comprising a processor communicatively coupled to the
imaging subsystem and configured to: (i) receive a captured image,
(ii) evaluate the structured-light pattern in the captured image,
(iii) obtain, from the evaluation, the range of each pixel in the
captured image, and (iv) determine, using the range for each pixel,
the dimensions of the object.
12. The structured-light dimensioning system according to claim 11,
wherein the structured-light dimensioning system is handheld.
13. The structured-light dimensioning system according to claim 11,
wherein the lens is an f-theta lens.
14. The structured-light dimensioning system according to claim 11,
wherein the structured-light pattern comprises the sub-patterns
arranged according to a square grid.
15. The structured-light dimensioning system according to claim 14,
wherein the sub-patterns are not overlapping.
15. (canceled)
16. The structured-light dimensioning system according to claim 11,
wherein the radiated light is infrared light.
17. The structured-light dimensioning system according to claim 11,
wherein the laser array is an array of vertical cavity surface
emitting lasers (VCSELs).
18. The structured-light dimensioning system according to claim 11,
wherein the lenslets comprise more than one optical element.
19. A method for creating a repeating optical pattern, the method
comprising: projecting light from a laser array comprising a square
grid of co-directed lasers; collimating the light from each laser
with a lenslet in a lenslet array to form a set of co-directed
laser beams arranged according to the square grid; focusing the
light from each laser beam onto a diffractive optical element (DOE)
using an f-Theta lens, each laser beam focused at a particular
incident angle determined by the laser beam's position in the
square grid; and diffracting, using the DOE, the light from each
laser beam to form a sub-pattern, wherein each laser beam's
sub-pattern propagates along a particular angle determined by the
particular laser beam's incident angle so that the sub-patterns
form a repeating optical pattern.
20. The method according to claim 19, wherein the repeating optical
pattern comprises sub-patterns arranged according to a square grid.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to optical dimensioning
systems and, more specifically, to an optical pattern projector
used for projecting a structured-light pattern onto an object for
dimensioning.
BACKGROUND
[0002] Optical dimensioning systems measure the dimensions and/or
volume of an item (e.g., a package for shipment) automatically and
with no manual measurements. One approach to optical dimensioning
requires the projection of an optical pattern (i.e., structured
light) onto the object being measured. Digital images of the object
and the reflected pattern may be captured and analyzed to determine
the item's physical dimensions.
[0003] An optical pattern projector creates and projects the
optical pattern necessary for dimensioning. The optical pattern
typically includes repeating patterns (i.e., sub-patterns) of light
spots (i.e., dots). A variety of methods to form the repeating
optical pattern exists.
[0004] One method uses a single laser and two diffractive optical
elements (i.e., DOE's). Here, the laser generates a laser beam that
is directed at the first DOE to create a sub-pattern. Next, light
from the first DOE is directed at a second DOE, which replicates
the sub-pattern to form the repeating optical pattern.
[0005] Another method to create the optical pattern uses a custom
laser array to form the sub-pattern of light. Light from the custom
laser array is directed at a DOE to replicate the sub-pattern and
form the optical pattern.
[0006] The methods thus far described have similar drawbacks. The
use of two DOE's and the use of a custom laser array increase the
cost and complexity of the optical pattern projector. A need,
therefore, exists for a simpler optical pattern projector for
structured-light dimensioning.
SUMMARY
Optical Pattern Projector
[0007] Accordingly, in one aspect, the present invention embraces
an optical pattern projector for projecting an optical pattern onto
an object. The optical pattern projector includes a laser array, a
lenslet array, a lens, and a diffractive optical element (DOE).
[0008] The optical pattern projector's laser array includes a
plurality of lasers. The lasers are arranged in an equal-spaced,
grid pattern. The lasers are configured to radiate light in the
same direction, and in one exemplary embodiment, the laser array is
an array of vertical cavity surface emitting lasers (VCSELs). In
another embodiment, the laser array may include over 100 VCSELs. In
still another exemplary embodiment, the lasers radiate infrared
light.
[0009] The optical pattern projector's lenslet array includes a
plurality of lenslets arranged so that each lenslet is aligned with
a particular laser. The lenslet array is positioned in front of the
laser array to focus the radiated light from the lasers into a
plurality of collimated laser beams. In an exemplary embodiment, a
lenslet includes more than one optical element.
[0010] The optical pattern projector's lens is positioned in front
of the lenslet array and is sufficiently large (i.e., has a
diameter large enough) to receive all of the laser beams. The lens
redirects each laser beam along a particular incident angle
determined by the laser beam's spatial position in the grid
pattern. In an exemplary embodiment, the lens is an f-theta
lens.
[0011] The optical pattern projector's DOE is positioned in front
of the lens. The DOE receives all of the laser beams and, for each
laser beam, creates a sub-pattern. The DOE projects each
sub-pattern along a particular angle determined by the particular
laser beam's incident angle.
[0012] The sub-patterns are projected onto a target (i.e., object,
item, etc.), where they combine to form an optical pattern. In an
exemplary embodiment, the sub-patterns are identical. In another
exemplary embodiment, the sub-patterns are arranged according to
the grid pattern. In still another exemplary embodiment, the
sub-pattern includes a non-uniform pattern of light spots, and in
some cases, the sub-pattern includes 3-15 light spots.
Structured-Light Dimensioning System
[0013] In another aspect, the present invention embraces a
structured-light dimensioning system for determining the dimensions
of an object. The dimensioning system includes an optical pattern
projector, an imaging subsystem, and a range mapping subsystem. In
an exemplary embodiment, the structured-light dimensioning system
is handheld.
[0014] The dimensioning system's optical pattern projector projects
a structured-light pattern onto an object. The optical projector
includes a laser array, a lenslet array, a lens, and a DOE.
[0015] The optical pattern projector's laser array includes a
plurality of equally spaced lasers arranged in a grid pattern. The
lasers array is configured so each laser radiates light in the same
direction. In an exemplary embodiment, the light radiated from the
laser array is infrared light. In another exemplary embodiment, the
laser array is an array of vertical cavity surface emitting lasers
(VCSELs).
[0016] The optical pattern projector's lenslet array includes a
plurality of lenslets, each lenslet positioned in front of one
laser in the laser array. The lenslets focus the radiated light
form the lasers into a plurality of collimated beams. In an
exemplary embodiment, the lenslets include more than one optical
element.
[0017] The optical pattern projector's lens is positioned in front
of the lenslet array. The lens is large enough to receive all of
the laser beams. The lens redirects each laser beam along a
particular incident angle, wherein a particular incident angle is
determined by the lasers beam's spatial position within the grid
array. In an exemplary embodiment, the lens is an f-theta lens.
[0018] The optical pattern projector's DOE is positioned in front
of the lens. The DOE creates a sub-pattern for each laser beam and
projects each sub-pattern towards the object along a particular
angle determined by the particular incident angle of the laser
beam. In other words, a particular laser beam's position in the
laser array determines the angle at which a particular sub-pattern
is projected.
[0019] The sub-patterns combine to form the structured-light
pattern. In an exemplary embodiment, the structured-light pattern
is the combination of sub-patterns arranged according to a square
grid. In another exemplary embodiment, the sub-patterns in the
structured-light pattern do not overlap. In still another exemplary
embodiment, each sub-pattern includes 3 to 15 spots of light.
[0020] The dimensioning system's imaging subsystem captures images
of the structured-light pattern transmitted by the optical pattern
projector and reflected from the object.
[0021] The dimensioning system's range mapping subsystem includes a
processor that is communicatively coupled to the imaging subsystem.
The processor is configured to receive an imaged captured by the
imaging system and evaluate the structured-light pattern in the
image. From the evaluation, the range of each pixel in the captured
image is obtained. Using the range for each pixel, the dimensions
of the object are determined.
Method for Creating a Repeating Optical Pattern
[0022] In another aspect, the present invention embraces a method
for creating a repeating optical pattern. The method includes the
step of projecting light from a laser array. The laser array
includes a square grid of co-directed lasers. The method also
includes the step of collimating the light from each laser with a
lenslet. The lenslet is part of a lenslet array that functions to
form a set of co-directed laser beams arranged according the square
grid. The method also includes the step of focusing the light from
each laser beam onto a DOE using an f-theta lens. The f-theta lens
focuses each laser beam along a particular incident angle
determined by the laser beam's position in the square grid.
Finally, the method includes the step of diffracting the light from
each laser beam to form a sub-pattern. Each sub-pattern propagates
along a particular angle that is determine by the incident angle of
the particular laser beam. In this way, the sub-patterns combine to
form a repeating optical pattern. In an exemplary embodiment, the
sub-patterns are arranged according to a square grid.
[0023] The foregoing illustrative summary, as well as other
exemplary objectives and/or advantages of the invention, and the
manner in which the same are accomplished, are further explained
within the following detailed description and its accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 graphically depicts elements of an optical pattern
projector according to an exemplary embodiment of the present
invention.
[0025] FIG. 2 schematically depicts a block diagram of a
structured-light dimensioning system according to an exemplary
embodiment of the present invention.
[0026] FIG. 3 depicts a flow chart of a method for creating a
repeating optical pattern according to an exemplary embodiment of
the present invention.
DETAILED DESCRIPTION
[0027] In one aspect, the present invention embraces an optical
pattern projector for a structured-light dimensioning system that
utilizes a standard laser array and a single diffractive optical
element.
[0028] The exemplary optical pattern projector shown in Figure
(FIG. 1 utilizes a plurality of light sources (i.e., lasers)
arranged in an array to radiate light in the same direction.
[0029] An array of vertical cavity surface emitting lasers (i.e.,
VCSELs) are suitable for use as the optical pattern projector's 10
laser array 1 for a few reasons. First, the VCSEL array may be
fabricated into a two-dimensional array using standard
semiconductor materials and standard semiconductor fabrication
techniques. Next, the low threshold current requirements of the
VCSEL enable high-density arrays. Next, the VCSELs in the array
typically radiate light in a direction that is perpendicular to the
substrate (i.e., package), allowing for convenient alignment in a
larger optical system. Finally, the light from a VSCEL (i.e., a
"dot") is substantially circular, making it suitable for forming
the optical patterns used for dimensioning.
[0030] The lasers 1a in the laser array 1 may be physically
arranged in a specific geometry (e.g., rectangular grid, hexangular
grid, etc.). Different array sizes are possible (e.g., 3.times.9)
and depend on the pattern requirements for dimensioning (e.g.,
overall pattern size, replicated pattern frequency, etc.).
[0031] The lasers 1a in the laser array 1 are typically identical,
each radiating light with a particular wavelength (e.g., 780-900
nanometers (nm)), a particular power, and (in some cases) a
particular polarization.
[0032] The optical power from the laser array 1 is adjustable. For
dimensioning applications, the optical power may be configured at
levels considered safe for normal use at typical dimensioning
ranges (e.g. 0.5-5 meters).
[0033] The lasers 1a in the laser array 1 may be electrically
addressed individually or in groups and driven to generate either
pulsed of continuous (i.e., CW) radiation. In an embodiment of the
present invention, the lasers simultaneously radiate CW light for a
period corresponding to the dimensioning process. In another
embodiment of the present invention, a subset of the lasers in the
laser array radiate CW light for a period corresponding to the
dimensioning process.
[0034] A laser 1a in the laser array 1 typically radiates light
divergently. This light may formed into a collimated laser beam
using a small lens (i.e., lenslet) positioned in front of the
laser. Thus a lenslet array 2 including a plurality of lenslets 2a
(e.g., one for each laser) may be positioned in front of the laser
array 1 to form a plurality of collimated laser beams. The laser
beams are co-directed and are typically co-linear. The lenslet
array 2 typically includes identical lenslets 2a. The lenslets may
be discrete. While single lens elements are typical, each lenslet
2a may utilize multiple optical elements (e.g., lenses, filters,
etc.). The lenslet array may be formed from a common substrate
using semiconductor-processing technology. In some embodiments, an
opaque film may be applied to the areas between lenslets to block
stray light.
[0035] The lenslet array 2 is positioned in front of laser array 1
at a distance determined by the lenslet characteristics (e.g.,
f-number) and the radiated light characteristics (e.g., a full
pattern angle). The positioning may be accomplished by integrating
the lenslet array 3 and the laser array 1 within a common package.
Alternatively, the lenslet array 3 may be positioned in front of
the laser array 1 using a separate mechanical structure. Fine
mechanical adjustments in position of one or more lenslets (or
VCSELs) may be possible. In a possible embodiment, this adjusting
of the position of one or more lenslets may be used to change the
projected pattern.
[0036] A lens 3 having a diameter large enough to capture all of
the collimated laser beams is positioned in front of the lenslet
array 2 to focus (i.e., redirect) the collimated laser beams (i.e.,
laser beams). Each laser beam is redirected by the lens 3 to a
particular incident angle determined by the laser-beam's position
within the laser array 1.
[0037] The lens 3 focuses the laser beams onto a diffractive
optical element (DOE) 4, which is positioned at (or near) the focal
plane of the lens 4. In a possible embodiment, the lens 3 is an
f-theta lens. An f-theta lens provides a flat field as opposed to
focusing light onto a spherical plane. An f-theta lens also
provides a linear mapping of position/angle. These aspects may be
desirable for creating the optical pattern.
[0038] The lens 3 may be fabricated using techniques known to those
skilled in the art using materials transparent to the light
radiation (e.g., glass, fused silica, polycarbonate, etc.). In some
embodiments, the lens maybe coated with an antireflection coating
to improve throughput, reduce reflections, and/or filter
stray-light.
[0039] The optical pattern projector's DOE 4 diffracts a collimated
laser beam in a plurality of beams. The plurality of beams form a
sub-pattern of light spots (i.e., dots) 5 on a target.
[0040] As shown in FIG. 1, the DOE 4 receives a plurality of laser
beams. Each laser beam creates an identical sub-pattern (e.g., a
pattern of light spots). Each sub-pattern 6 typically includes the
same pattern of light spots 5. The spots in the sub-pattern may be
different sizes. The sub-pattern includes the number of light spots
necessary for dimensioning. For example, in one possible
embodiment, the sub-pattern 6 includes 3-15 light spots. In
addition, the separation between dots 5 may be chosen so that no
touching dots within the sub-pattern are allowed.
[0041] Sub-patterns 6 are projected onto a target (i.e., object)
and combine to form an optical pattern 7 (i.e., structured-light
pattern). The optical pattern's sub-patterns may be sized so that,
for ranges expected in dimensioning (e.g., 0.5 to 4.5 meters), the
sub-patterns 6 do not overlap. The distribution of the spots (i.e.,
dots) 5 in the sub-pattern may be chosen to insure that the optical
pattern 7 is symmetrical relative to the center. Further, dots at
the edges of a sub-pattern may be configured so that when combined
with other sub-patterns do not form touching light spots.
[0042] The optical pattern projector 10 thus far described may be
part of a structured-light dimensioning system 20 as shown in FIG.
2. The structured-light dimensioning system 20 can measure the
dimension of an object 21 (e.g., volume) placed in its field of
view 22 by first projecting a known optical pattern onto the object
21.
[0043] Images of the object 21 and the optical pattern 7 may be
captured using an imaging subsystem 23 positioned in proximity to
the optical pattern projector (e.g., stereoscopically). The imaging
subsystem 23 captures images of the object 21 and the projected
light pattern 7. To accomplish this, the imaging subsystem 23 may
use an imaging lens to render a real image of the imaging lens's
field of view 22 onto an image sensor. This imaging lens field of
view 22 overlaps at least partially with the projected light
pattern 23. The image sensor may be a charge coupled device (i.e.,
CCD) or a sensor using complementary metal oxide semiconductor
(i.e., CMOS) technology. The image sensor includes a plurality of
pixels that sample the real image and convert intensity into an
electronic signal.
[0044] A range mapping subsystem 24 having a processor (e.g., one
or more controller, digital signal processor (DSP), application
specific integrated circuit (ASIC), programmable gate array (PGA),
and/or programmable logic controller (PLC)) configured by
processor-executable instructions (i.e., software) stored in at
least one non-transitory storage medium (i.e., memory) 26 (e.g.,
read-only memory (ROM), flash memory, and/or a hard-drive), can
processes the captured images and measure any distortions to the
optical pattern 7 (e.g., distortions to the pattern caused by the
object). The distortions to the optical pattern may analyzed to
produce a range image. A range image has pixels that spatially
match the field of view, like an image, but that have grayscale
values that correlate with range. The range image may be processed
to determine the dimensions of the object 21.
[0045] The subsystems in the structured-light dimensioning system
are connected via a couplers (e.g., wires or fibers), buses, and
control lines to form an interconnection subsystem 27 that allows
communication and interaction.
[0046] A method for creating a repeating optical pattern according
to an exemplary embodiment of the present invention is shown in
FIG. 3. The method includes the step of projecting light from a
laser array 31. The laser array includes a square grid of
co-directed lasers. The method also includes the step of
collimating the light from each laser with a lenslet array 32. The
method also includes the step of focusing the light from each laser
beam onto a DOE using an f-theta lens 33. The f-theta lens focuses
each laser beam along a particular incident angle determined by the
laser beam's position in the square grid. Finally, the method
includes the step of diffracting the light from each laser beam to
form a sub-pattern 34. Each sub-pattern propagates along a
particular angle that is determine by the incident angle of the
particular laser beam. The sub-patterns combine to form a repeating
optical pattern 35.
[0047] To supplement the present disclosure, this application
incorporates entirely by reference the following commonly assigned
patents, patent application publications, and patent
applications:
To supplement the present disclosure, this application incorporates
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[0315] In the specification and/or figures, typical embodiments of
the invention have been disclosed. The present invention is not
limited to such exemplary embodiments. The use of the term "and/or"
includes any and all combinations of one or more of the associated
listed items. The figures are schematic representations and so are
not necessarily drawn to scale. Unless otherwise noted, specific
terms have been used in a generic and descriptive sense and not for
purposes of limitation.
* * * * *