Optical triangulation sensor for distance measurement

Abstract

An optical triangulation sensor for distance measurement is described herein. In accordance with one embodiment, the apparatus comprises a light source for the generation of structured light, an optical reception device, at least one attachment element and a carrier with a first groove on a lateral surface of the carrier, wherein the light source and/or optical reception device is at least partially arranged in the first groove and is held in place on the carrier by the attachment element.

Claims

1. A sensor, comprising: a light source for generating structured light which has a first optical axis; an optical reception device with a second optical axis; a carrier through which a light channel runs; a light sensitive sensor is arranged on an outer surface of a rear side of the carrier such that light passing through the light channel at least partially falls onto the sensor; wherein the light sensitive sensor is only connected with the carrier on two or more mounting surfaces along an attachment line X; and wherein the sensor is an optical triangulation sensor.

2. The sensor in accordance with claim 1, wherein the mounting surfaces protrude from the rear side of the carrier.

3. The sensor in accordance with claim 1, wherein the attachment line stands normal to a plane defined by the first and the second optical axes.

4. The sensor in accordance with claim 1, wherein the attachment line is positioned on the carrier such that light from the light source that is reflected from far distant objects falls approximately onto the attachment line.

5. The sensor in accordance with claim 1, wherein the light sensitive sensor has a sensor circuit board on a light sensitive chip is arranged, wherein the sensor circuit board is connected with a further electronic circuit board via flexible bridges, wherein the sensor circuit board is only connected with the carrier on the mounting surfaces along the attachment line, and wherein the further electronic circuit board is also connected with the carrier.

6. The optical triangulation sensor in accordance with claim 5, wherein the sensor circuit board, with the exception of the bridges, is separated from the further electronic circuit board by cutouts.

7. A sensor, comprising the following: a light source for generating structured light; an optical reception device; an attachment element or an adhesive; a carrier with a first groove on an outer surface of a lateral side of the carrier, wherein the light source, the optical reception device, or a combination thereof, are at least partially arranged in the first groove and held in place on the outer surface of the lateral side of the carrier by the attachment element or the adhesive, wherein the first groove, the light source, the optical reception device, or a combination thereof, are formed such that the light source, the optical reception device, or a combination thereof only contact the carrier along two parallel contact lines; and wherein the sensor is an optical triangulation sensor.

8. The sensor in accordance with claim 7, wherein the carrier has, in a middle segment of the first groove a recess, so that the light source, the optical reception device only rest on two or more interrupted segments of the contact lines (A,B).

9. The sensor in accordance with claim 7, wherein the first groove has two lateral surfaces that form contact surfaces upon which the light source, the optical reception device, or a combination thereof, rest along the contact lines.

10. The sensor in accordance with claim 7, wherein the light source is at least partially arranged in the first groove, and wherein the carrier has a second groove in which the optical reception device is at least partially arranged.

11. The sensor in accordance with claim 10, wherein the second groove and the optical reception device are formed such that the optical reception device only rests on the carrier along two contact lines.

12. The optical triangulation sensor in accordance with claim 11, wherein the carrier has, in a middle segment of the second groove a recess so that the optical reception device only rests on two or more interrupted segments of the contact lines.

13. The sensor in accordance with claim 11, wherein the second groove has two lateral surfaces that form contact surfaces upon which the light source, the optical reception device, or a combination thereof, rest along the contact lines.

14. The sensor in accordance with claim 10, wherein one part of a front side of the carrier is recessed and the second groove runs in a lateral surface of the two lateral surfaces from the front side of the carrier to the recessed part of the front side of the carrier.

15. The sensor in accordance with claim 14, wherein the second groove adjoins a light channel running from the recessed part of the front side of the carrier to a rear side of the carrier, and wherein a light sensitive sensor is arranged on the rear side of the carrier.

16. The sensor in accordance with claim 7, wherein the carrier exhibits a higher degree of stiffness than a stiffness of the attachment element.

17. An apparatus having an optical distance-measuring sensor, the optical distance-measuring sensor comprising: a light source for generating structured light which is sent to an obstacle; a light sensitive sensor that detects light reflected by the obstacle; a carrier to which the light source and the light sensitive sensor are attached; wherein the optical distance-measuring sensor is installed in an optically enclosed installation chamber; wherein the installation chamber has a window, through which light emitted from the light source can exit and light reflected by an obstacle can enter; and wherein the apparatus is a mobile robot.

18. The apparatus in accordance with claim 17, wherein the optical distance-measuring sensor comprises an analysis unit in electronic communication with the light sensitive sensor.

19. The apparatus in accordance with claim 17, wherein the light source is a monochromatic light source generating light of almost one wave length, and wherein the window acts as an optical filter, which is arranged to filter out at least partially light having a wave length that differs from the wave length of the light emitted by the light source.

20. The apparatus in accordance with claim 17, wherein inside of the installation chamber is coated with a light absorbing coating having a reflection factor of less than 0.1.

21. The apparatus in accordance with claim 17, wherein a shield is attached to the carrier to shield diffused light of the light source, to prevent diffused light of the light source to reach the light sensitive sensor, or a combination thereof.

22. The apparatus in accordance with claim 17, wherein the at least one window is provided on the inside with an antireflection coating.

23. The sensor in accordance with claim 1, wherein the sensor is mounted on a robot.

24. The sensor in accordance with claim 1, wherein the carrier is approximately prism-shaped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows the physical principle of distance measurement by means of an electro-optical triangulation sensor.

(2) FIG. 2 shows an exploded view of an embodiment of an apparatus in accordance with the present disclosure.

(3) FIG. 3 shows an embodiment of a groove in a carrier for the mounting of a radiation source.

(4) FIGS. 4-7 show various examples of attachment elements for attaching a radiation source onto the carrier in accordance with FIG. 3.

(5) FIG. 8 shows a shielding structure on a carrier.

(6) FIG. 9 shows an embodiment of a carrier for the attachment of an optical reception device.

(7) FIG. 10 shows an embodiment of a camera circuit board with a light sensitive sensor.

(8) FIG. 11 shows an embodiment of a work machine.

(9) In the figures, like reference numerals designate the same or similar components, each having the same or similar meaning.

DETAILED DESCRIPTION

(10) In FIG. 1 the principle of optical triangulation is illustrated. Using a light source 20 for structured light (e.g. a light diode or a laser diode having, if necessary, an optical device), a suitable optical reception device 23 (i.e. a light collector such as a lens or lens system) and a sensor 30 (e.g. an active pixel sensor, also known as a CMOS sensor), a distance d to an object 90 can be determined. The light source 20 emits a (structured, e.g. fanned to a line) light beam 91, which is reflected by (i.e. diffused back by) an object 90 (obstacle) at least partially in the direction of the optical reception device 23. The reflected beams 92, 93, 94 (only a selection) are directed to sensor by the optical reception device 23. With the aid of the sensor 30, in particular the incident angle α can be determined. Using the incident angle α and a predefined distance h between the light source 20 and the optical reception device 23, the distance d can be calculated. The predefined distance h is determined by the sensor assembly and may lie, for example, in a range of 1 cm to 10 cm, for example in a range of 2 cm to 7 cam. In the present example, h is the standard distance (normal distance) of the optical axes from the light source 20 and the optical reception device 23.

(11) FIGS. 2A and 2B show the same example of an optical triangulation sensor in a perspective view from various angles. The triangulation sensor comprises a (e.g. approximately prism shaped) carrier 10, a light source 20 and an optical reception device 23 which may be consolidated in a camera module together with a CMOS sensor 30. The carrier 10 has, on a first lateral surface, a first recess, designated as a first groove 12. Further, the carrier 10 may be made of a material with a low coefficient of thermal expansion such as plastic, ceramic or metal. The carrier 10, for example, may be manufactured by plastic injection molding. The carrier 10, may also be made of a material with a high modulus of elasticity. The light source 20 is arranged in the first groove 12. The light source 20 for structured light may have an (adapter) housing 21, a radiation source 22 (e.g. a laser diode or a light-emitting diode), and may also comprise a collimator lens and/or a line generator. The housing 21 prevents the radiation source 22 from being damaged by external influences. The light source 20 may exhibit, (at least in certain parts) a round cross section and may be held in place on the carrier 10 with the aid of an attachment element 24. The light source 20 may, alternatively, also exhibit any other cross section form, for example an oval, rectangular, polygonal or rhombus shaped cross section. As a rule, then, the light source 20 is of a cylindrical or prism form. The cross section of the light source 20 need not be the same along its entire length (i.e. along its optical axis). The housing 21 of the light source 20 may have, e.g. at one end, a protrusion on which, e.g. a collimator lens is arranged. Various exemplary embodiments of the attachment element 24 will be described further on. As an alternative or in addition to the attachment element 24, an adhesive may also be used to hold the light source 20 in place on the carrier 10 (see FIG. 2A, adhesive layer 24′). In some embodiments the attachment element 24 will only be needed temporarily, until the adhesive has hardened, and it may be removed afterwards.

(12) The light source 20 for structured light can emit focused, punctiform (point-shaped) or line-shaped (or any otherwise structured) light 91. When the apparatus is in operation, the light source 20 can emit light 91 continuously. As an alternative, the light source 20 may also only emit light 91 in intervals or when specifically activated. The light 91 may exhibit a wavelength between, e.g. 400 nm and 1000 nm. Larger and smaller wavelengths are also possible.

(13) In a further example embodiment, the carrier 10 may have a second recess designated as a groove 13. In this, the optical reception device 23 or the entire camera module (which includes the optical reception device 23) can be arranged and may also be held in place in or on the groove 13 with the aid of an attachment element 25. In the illustrated example, the groove 13 is arranged symmetrically to the groove 12. The grooves 12 and 13 are arranged on opposite lateral surfaces of the carrier 10. A different arrangement, e.g. on one same lateral surface, is also possible.

(14) The optical reception device 23 can be, for example, an optic lens. This optical reception device 23 collects and focuses the reflected radiated light (beams 92, 93, 94). The optical reception device 23 may be made of, for example, glass or plastic and may also comprise numerous individual lenses. The reflected beam 92, 93, 94 is conveyed to the sensor 30 by the optical reception device 23. Additionally or as an alternative, the optical reception device 23 may also have other optical components such as, for example, one or more mirrors.

(15) The sensor 30 can be designed to be able to detect at least part of the reflected beam 92, 93, 94. Generally a CMOS sensor (active pixel sensor) or a CCD sensor (charge coupled device) is used. As an alternative, various kinds of photodiodes (e.g. a position sensitive device, PSD, and a quadrant photodiode, QPD) may be considered for sensor 30.

(16) In the example described above, the optical reception device 23 and the sensor 30 are consolidated in a camera module. In a further example embodiment, the optical reception device 23 and the sensor 30 are attached separately from each other. Such a case is also illustrated in FIGS. 2A and 2B. Here the optical reception device 23 is arranged in the second groove 13, whereas the groove 13 does not extend over the entire depth of the carrier 10. In order that the optical reception device 23 be able to convey the reflected beam further to the sensor 30, the sensor is arranged behind the optical reception device 23. As shown in FIGS. 2A and 2B, the optical reception device 23 and the sensor 30 may be attached behind each other on two opposite main surfaces of the carrier 10 (front and rear side) and may be aligned with each other, whereas the groove 13 is arranged on a step-like ledge of the carrier 10 and therefore does not extend along the entire diameter of the carrier 10. The ledge is formed by recessing the lower area of front side of the carrier 10. The groove 12 thus runs in a lateral surface from the front side of the carrier 10 to the recessed front side, whereas an opening, designated as the light channel, adjoins the groove 13 through the recessed front side, the light being able to pass through the opening and up to the rear side of the carrier (on which the sensor 30 is arranged). The mounting of the sensor 30 (i.e. of a sensor circuit board on which a light sensitive chip is arranged) will be described in detail later with reference to FIGS. 8 and 9.

(17) In FIG. 3 a possible design of the groove 12, arranged in the upper lateral surface (top surface) of the carrier 10, is shown. FIG. 3A shows a perspective view, FIG. 3B shows a top view. By means of the specific form of the groove 12, mounting areas 11 between the light source 20 and the carrier 10 are defined that allow for a linearly shaped contact between the light source 20 and the carrier 10. The cross section of the groove 12 may be designed, for example, triangular, rectangular, trapezoidal or rhombus shaped. Other forms are also possible. In general, the cross section of the groove 12 and the light source 20 (i.e. their housing) are formed such that the light source 20 inserted in the groove 12 only rests along two lines A and B (contact lines) on the mounting areas 11 that are formed by the lateral walls of the groove 12. In the example embodiment shown here, the contact lines A, B run parallel to the longitudinal axis (optical axis) of the light source 20. As can also be inferred from FIGS. 3A and 3B, the cross section of the groove 12 is not uniform throughout the entire groove. The cross section of groove 12 is, for example, only at the two ends of the groove 12 approximately triangular, between these, however, (in the longitudinal direction of the groove) it is rectangular. This means that the groove 12 may be enlarged in its middle region by the recess 14, thereby interrupting the mounting areas 11, such that the light source 20 now only rests on two segments each (A1, A2 and B1, B2) of the contact lines A and B. The remaining mounting areas 11 along the contact lines may be relatively short (approximately 1 mm), thus forming a total of four approximately “punctiform” mounting areas at which the light source 20 contacts the carrier 10. By virtue of such a design of carrier 10, thermally induced tension is not so easily transferred to the light source 20. The position of the transmission unit is only minimally altered by the thermal expansion of the carrier, and in a defined, reversible manner. Measurement accuracy improves. The statements made with reference to groove 12 equally apply to groove 13 and the optical reception device 23 attached therein.

(18) In FIGS. 4 through 7 various attachment elements 24 are exemplarily shown. As can be seen from the FIGS. 4 to 7, the attachment element 24 can be implemented as one, two or numerous parts. The attachment elements 24 are designed to press the light source 20 against the carrier 10, thereby providing its friction-locked attachment to the carrier 10. The information given with reference to the attachment elements 24 equally apply to the attachment of the transmission unit 20 in the groove 12, as well as to the attachment of the optical reception device 23 in the groove 13. The force effect of the attachment elements 24 on the light source 20 and the optical reception device 23 can be directed in the direction of their respective linear mounting areas 11. The attachment elements 24 are elastic and can therefore yield to a thermal expansion of the light source 20. In addition to this, they can apply a pre-defined force to the light source 20 (e.g. in a direction normal to the longitudinal axis of the light source 20), thereby preventing the radiation unit 20 from becoming displaced in the event of impacts or vibration. At the same time, the force can be defined so as not to impair the functionality of the light source 20. Further, an adhesive may additionally be applied to the points of connection between light source 20 and carrier 10 and/or between light source 20 and attachment element 24. Generally the carrier exhibits a higher degree of stiffness than a stiffness of the attachment elements. Generally this means that, in the event of thermal expansion, first and foremost the attachment element will yield, providing for a well-defined (predictable) behavior of the carrier.

(19) FIG. 4 shows a one-piece attachment element 24 that is screwed onto the carrier 10 by means of screw attachments. The attachment element 24 can be screwed onto the lateral surface of the carrier 10 on which the groove 12 is also disposed. As can be inferred from FIG. 4, the attachment element 24 can be made of a pre-contoured metal sheet or a suitably formed (e.g. by means of injection molding) plastic part that is pre-tensioned when the attachment element 24 is screwed onto the carrier 10, thus holding the transmission unit 20 in place in the groove 12.

(20) In the further embodiment of FIG. 5, the attachment element 24 is comprised of two parts. The two parts of the attachment element 24 are made of two pre-contoured metal sheets or suitably formed plastic parts, mounted at a certain distance from each other (on opposite sides of the groove 12) on the carrier 10. The two attachment elements 24 need not necessarily mechanically contact each other.

(21) FIG. 6 shows a further exemplary embodiment. Here the attachment element 24 is implemented as one part and is at least partially conjoined with the carrier 10. The attachment element 24 forms a kind of clamp that can be locked in place on the carrier (snap-in connection). As already mentioned in reference to the preceding figures, the attachment element 24 in FIG. 6 can be appropriately contoured or formed in advance, so that it is pre-tensioned when the light source 20 is mounted, exerting a force on the transmission unit 20 and pressing it against the carrier 10.

(22) FIG. 7 shows an attachment element 24 that is cohesively bonded to the carrier 10. The cohesive bond can be realized, for example, by gluing, welding or soldering. Alternatively, the carrier 10 can be manufactured in one piece together with the attachment element 24 (e.g. by injection molding). The attachment element can be pre-tensioned so that, when the transmission unit 20 is mounted, a force is exerted on the transmission unit 20 and it is pressed against the carrier 10.

(23) FIG. 8 shows a further embodiment. As mentioned above, the sensor 30 can form a component (camera module) together with the optical reception device 23. As an alternative, however, it is also possible for the sensor 30 to be attached to the carrier 10 independently of the optical reception device 23. The sensor 30 (sensor chip including sensor circuit board) is also attached to the carrier on defined mounting areas 41, 42 along a line designated as attachment line X (e.g. by means of screws). The attachment line X, with the “attachment points” that are defined by the mounting areas, extends, for example but not necessarily, symmetrically to a light channel 43 that runs through the carrier 10 and through which light from the optical reception device (not shown in FIG. 8) can reach the sensor 30.

(24) The mounting areas 41, 42 may, for example, protrude from the surface of the carrier 10 (e.g. in the form of pins, sleeves, etc.), allowing the sensor 30 to be mounted parallel to the surface of the carrier. In this case the sensor only rests on the at least two mounting areas 41, 42 that are arranged along the attachment line X, wherein the attachment line X runs normal to the plane formed by the optical axes of light source 20 and optical reception device 23. Consequently, the sensor 30 and the carrier 10 can thermally expand independently of each other without causing significant mechanical tension in the sensor 30 and the resulting expansion, at least not in a direction that is relevant for the distance measurement. This means a thermal expansion of the sensor 30 relative to the carrier 10, in a direction at a right angle to attachment line X and normal to the optical axis of the optical reception device, is not impaired.

(25) Due to the elevated attachment of the sensor 30, a gap is formed between the light sensitive sensor 30 and the surface of the carrier 10, through which undesired diffused light might have a negative effect on the sensor measurement. In order to counteract this, a shielding structure 40 may be arranged on a lateral side of the carrier 10 facing the sensor 30 which at least partially surrounds the light channel 43 and also protrudes from the surface of the carrier. This shielding structure 40 may be realized in a ring form, for example. It is, however, also possible for the shielding structure 40 to be realized in a rectangular form. The shielding structure 40 may be as high as or lower than (relative to the surface of the carrier) the mounting areas 41, 42.

(26) The mounting areas 41, 42 may be at a pre-defined standard distance from the underlying lateral surfaces of the carrier 10. The distance of the sensor 30 to the carrier 10 and the focal length of the optical reception device 23 are matched to each other. The position of attachment line X (i.e. its distance to the optical axis of the light source 20) may be selected such that reflected beams 92, 93, 94 of a distant (theoretically infinitely distant) object 90 strike the attachment line X. This range (great distances) demands the highest degree of measurement accuracy. At greater distances, the position at which the reflected beams 92, 39, 94 fall into the optical reception device converge to a threshold value. “Great distances” refers to distances at the far end of the distance measurement range, e.g. in the range of 5 to 10 m. By selecting the attachment line in the manner described above, the effect of a thermal expansion of the sensor 30 relative to the carrier 10 is minimized in this range. The attachment line X may therefore lie at a height at which beams reflected from far distant objects strike the sensor. When the optical axis 96 of the optical reception device 23 runs approximately parallel to the optical axis 97 of the light source 20, the attachment line X lies at the height of the optical axis 96 of the optical reception device 23.

(27) FIG. 9 shows an exploded view of the carrier of FIG. 8, together with mounting surfaces 41, 42, the shielding structure 40 and the sensor 30 that is attached to the attachment elements 41, 42 along a line X. In one embodiment, the sensor 30 is arranged on a circuit board. An analysis unit or other electronic components may also be mounted on this circuit board. This may lead to a circuit board of a size that can no longer be attached along the attachment line X with sufficient mechanical stability. In order to nevertheless continue avoiding mechanical tension that might impair measurement accuracy, the circuit board is realized as two or more parts that are connected with each other such that no significant forces can be transmitted from one part to another. For example, the connection between the two parts might be flexible or elastic. The elastic (flexible) connections between the circuit boards could be designed to contain electrical connections. Smaller relative displacements between the individual circuit boards can thus take place without producing great mechanical tension. Connecting two separate circuit boards with cables in an elaborate production step may thus be avoided.

(28) FIG. 10 shows an example of a sensor 30 with a circuit board 37 in which two cutouts 38 and 38′ are formed, the cutouts 38, 38′ being formed such that a sensor circuit board 34 for the light sensitive sensor chip 31 remains in between, the sensor chip being connected with the surrounding circuit board only via one or more thin flexible bridges. The cutout can be produced, for example, by milling, punching or cutting. In the present example, the sensor circuit board 34 is connected with the surrounding circuit board 37 via the two bridges 35 and 36. In FIG. 10 the attachment line X is also once again shown (cf. FIGS. 2 and 8), along which the sensor circuit board 34 is connected, at the positions 41′ and 42′, with the mounting areas 41 and 42 (see FIG. 9). The circuit board 37 surrounding the sensor circuit board 34 may contain additional electronic components 33 and may be attached to the carrier 10 at numerous positions 32. The thin, flexible bridges 35 and 36 bring about a mechanical decoupling (no or only very little transmission of force in a direction perpendicular to the attachment line) of the sensor circuit board 34 from the surrounding circuit board 37.

(29) In further embodiments the sensor 30 may have numerous sensor chips 31 arranged next to each other (along the attachment line X). In this case, the individual sensor chips 31 may be designed smaller than the entire image area of the optical reception device 23. In particular, the sensor chips 31 may be arranged in pre-defined (e.g. lying horizontally next to each other) segments of the image area of the optical reception device 23. It is thus possible to ensure that, even in case of large (lying in a horizontal plane) beam radiation angles of the light source 20, for example 120°, the reflected beams 92, 93, 94 will be received by using small, commonly sold sensor chips that are much less expensive than a larger one would be.

(30) After manufacturing a device for distance measurement, its calibration may be necessary. This calibration can be carried out, for example, at the average working temperatures of an installation. Alternatively it may be carried out for different working temperatures. The (possibly temperature dependent) calibration data may be optionally stored in a memory unit of the sensor 30.

(31) FIG. 11 shows a work machine 80 (e.g. a cleaning robot) with an optical triangulation sensor that may be constructed as described above in reference to the FIGS. 1 through 10. Here the triangulation sensor for distance measurement is attached to the work machine 80 in a suitable manner and can be employed by the work machine 80 to measure distances. For example, the distance measurement device may be arranged on the front side of the work machine 80, in the middle of the work machine 80 or at the rear on one side of the work machine 80. Further, the distance measurement device may be arranged such that it extends at least partially beyond the work machine 80, so that the distance measurement is not impaired by other components of the work machine 80. In a further embodiment of the work machine 80, the distance measurement device may be installed inside of the work machine 80 in an installation chamber. This protects the device for distance measurement from dust and other external influences. For example, the device may be located behind one or more windows. These windows are at least partially permeable for the emitted beam 91 and the reflected beams 92, 93, 94. The windows can function simultaneously as filters. Radiation having a wave length that differs from the wave length of the beam emitted by the light source 20 will be thus at least partially filtered out.

(32) Besides this, reflections within the inside of the work machine 80 can be reduced by various means. For this purpose the installation chamber may be provided with a low-reflecting inner coating or may be painted dark or it may be formed of a material that has a low reflection coefficient. The windows of the installation chamber may be made of a material that reflects as little as possible of the light 91 emitted by the light source 20 and, for example, may be provided with an non-reflecting coating. The degree of reflection of parts of the installation chamber may be less than 10%, for example. Generally, a screen 15 may be arranged either on the carrier 10 or and the work machine 80 such that undesired diffused light emitted by the light source 20 (see the upward running light beam 91′) is shielded off. The light source 20 emits light predominantly in a (i.e. horizontal) plane E. The screen 15 can in this case be designed and arranged to shield off diffused light that is deflected towards a point P lying above the plane E. In this manner, no undesired reflections caused by the diffused light falling on strongly reflecting objects can enter the optical reception device. The screen 15 may be, for example, a slit screen. Since, as a rule, diffused light that is deflected down does not cause problems, a “half slit screen”, i.e. a shield with a horizontally running edge, is also sufficient, whereby a, e.g. horizontally emitted main beam 91 is not impaired while the diffused light deflected upwards is nevertheless shielded off. The screen 15 may be employed in any of the embodiments of the triangulation sensor described here.