HoloProbe: Computer Generated Holographic Projection for Precise Sensing and Control in Manufacturing

Large field of view, non-contact, precision 3D sensing is an unmet technological need with applications in manufacturing and automation. Lidar and computer vision (including telecentric, stereoscopic, and structured light) cannot capture high precision (10 micron) details over a large field of view (on the scale of 1 meter). This technical limitation is a fundamental result of pixelation and geometric optics which would require collecting a >10 gigapixel image to achieve the previously discussed precision, even if all other technical challenges (depth resolution, focal depth, and noise) are ignored. Diffract Technologyĺs novel HoloProbe tool uses adaptive, large field of view, computer defined optics to provide precision 3D sensing and control. HoloProbe uses adaptive optics to refine measurements and provide reliable, precise measurements in-situ. Since HoloProbe does not depend on any moving components, this is a robust solution which can be easily incorporated into manufacturing systems such as 3D printers, CNC mills, and automated assembly systems. A primary focus of this project is applying these 3D measurement capabilities to automated system control. Precise, high-speed 3D measurements enables HoloProbe to act as a motion controller, directing where actuators such as motion stages or robotic arms should go. Due to the extraordinary precision of the HoloProbe sensor (with a 10 micron FWHMá point-spread-function), position control accuracy via the HoloProbe sensor can significantly surpass most industrial robots. Furthermore, since the HoloProbe sensor can also measure components and control multiple actuators, all of the actuators and object positions are measured using a single consistent coordinate system. As a result, the motions which are coordinated through the HoloProbe device are both accurate and precise. These capabilities promise to revolutionize manufacturing and automation by providing precise real-time measurements and system control.