Three-dimensional scanning device and methods

Abstract

A handheld data acquisition system for capturing three dimensional object shape data comprising a user feedback screen and a scanner module configured such that the scanner module may be rotated with respect to the feedback screen and the user may be able to scan objects including hard-to-reach areas while still being able to view feedback about the on-going scanning process.

What is claimed is: 
     
         1 . A data acquisition system, comprising:
 a display module;   a sensor module;   a light-emitting module.   
     
     
         2 . The data acquisition system of  claim 1 , wherein the sensor module comprises a first sensor and a second sensor. 
     
     
         3 . The data acquisition system of  claim 2 , wherein the second sensor has a larger field of view (FOV) than the first sensor. 
     
     
         4 . The data acquisition system of  claim 1 , wherein the display module is rotatable relative to the sensor module via a connection member. 
     
     
         5 . The data acquisition system of  claim 1 , wherein the light-emitting module comprises at least one of: a projector, an array of light emitting diodes (LEDs), or a light emitting screen. 
     
     
         6 . The data acquisition system of  claim 2 , wherein at least one of the first sensor and the second sensor has a primary camera axis and the light emitting module has a primary light emission axis such that an angle between the primary camera axis and the primary light emission axis is approximately 0 to 30 degrees. 
     
     
         7 . A method of scanning an object comprising:
 capturing scan data of a first object in a first scan mode;   comparing the scan data to a predetermined threshold; and   capturing scan data of the first object in a second scan mode based upon the comparison to the predetermined threshold.   
     
     
         8 . The method of  claim 7 , wherein the second scan mode comprises a higher resolution than the first scan mode. 
     
     
         9 . The method of  claim 7 , further comprising computing coverage or boundaries of 3D data relative to the first object identified in 2D images. 
     
     
         10 . The method of  claim 9 , wherein comparing the scan data to a predetermined threshold comprises comparing the coverage of the 3D data to the predetermined threshold. 
     
     
         11 . The method of  claim 7 , wherein the second scan mode initiates automatically and free of user input. 
     
     
         12 . A 3D scanning method comprising:
 capturing a plurality of 3D data sets of an object while the object is grasped and rotated by a hand;   identifying data portions that are not consistent among the plurality of 3D datasets;   removing the inconsistent portions of the 3D datasets to create trimmed datasets, wherein the inconsistent portions correspond to the hand;   aligning the trimmed datasets; and   combining the trimmed datasets to create a unified result that represents the shape of the object being scanned without the hand.   
     
     
         13 . The 3D scanning method of  claim 12 , wherein the method is performed without releasing the grasp on the object. 
     
     
         14 . A 3D scanning method, comprising:
 capturing one or more images of an object with a sensor;   displaying the one or more images of the object on a display; and   displaying real-time visual feedback while displaying the one or more images of the object regarding at least one of accuracy or data density of the one or more images.   
     
     
         15 . The 3D scanning method of  claim 14 , wherein the real-time visual feedback comprises differentiated areas on the object displayed in different colors or textures representing at least one of accuracy or data density.