Abstract:
Some embodiments provide a motion control system controlling an image projected from an underwater projection system in a water feature, pool, or spa. The system includes a rotatable base and a mirror support member hingedly coupled to the rotatable base. A first motor is coupled to the rotatable base and is configured to rotate the mirror support member in a first plane. A second motor is coupled to the rotatable base and a fixed mount, wherein the second motor is configured to rotate the rotatable base relative to the fixed mount thereby rotating the mirror support member in a second plane.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/957,418 filed Aug. 1, 2013, which is a continuation-in-part of U.S. patent application Ser. No. 13/626,871 filed Sep. 25, 2012, and also claims the priority of U.S. provisional patent application 61/678,622, filed Aug. 1, 2012, all of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    In applications having light projection, one technique to allow mechanical motion to direct the light in the x and y axis is to use two discrete mirrors with one mirror allowing for rotation of the image in the x axis which is further superimposed on another mirror allowing for further rotation in the y axis. An advantage of this system is simplicity—the two axes can be parked on a rotating shaft such as a motor or a galvanometer with a simple control mechanism to control the position of the mirrors. A principal problem with this type of control system is that the reflection occurs on two surfaces resulting in losses and inaccuracies from the mirror surfaces imperfections. These issues result in a reduction of image intensity and quality. The two mirror configuration also requires a larger size/footprint. The primary mirror may be small but the secondary mirror, which collects all the diverging light from the primary source will need to be larger. 
         [0003]    In addition, various methods exist for tip and tilting, x and y translation, of a single reflective surface. Some of them are used in sensitive applications such as in the aviation, space and medical fields and are very accurate, sometimes down to the milliradian. They use forces such as magnetic, mechanical, piezo, and other means of locomotion to tilt a system that is held in either a gimbal or a ball joint. Such systems need complex and carefully manufactured electronics to close a feedback loop allowing for proper functioning of the system rendering and tilt systems with a single reflective surface has a limited range of motion despite the higher resolution and cost, further limiting their applicability to most general applications. Alternately, other existing techniques that have a single reflective surface and employ a mechanical system need articulated arms and carefully designed ball joints to function, similarly saddling them with higher manufacturing costs and requiring larger footprints for deployment. 
         [0004]    Another technique of enabling a single reflective surface in more than one axis of rotation employs a primary rotation medium that is coupled to a secondary rotation medium which in turn rotates the minor. These devices actually move the second motor and as a result need more space for operation, again increasing the footprint of the system. The addition of a moving second motor adds mass to the moving components and increases inertia. The inertia of the motor can prohibit a smaller, lower power first motor from being used or from a small first motor to move with higher acceleration and deceleration. This higher inertia also renders such systems more prone to errors due to the larger moving masses. Further because the mirror is far from the main axis of rotation, the mirror surface has to be larger, making it impractical for limited physical space applications. These factors contribute to making these systems less accurate and requiring more space in a footprint for deployment in any control system. 
         [0005]    Thus, there exists a need for a device and a method that provides tip and tilt control on two axis, offers the ability for systems to calculate the relative or absolute position of the mount surface or element quickly and efficiently, provide for fixed motors which in turn lower motor torque and provide a lower inertia of moving components and be cost effective. The system also needs to provide the motion at high speed, have a small form factor /net volume, use smaller motors to save weight, reduce cost, reduce inertial interference, lower power consumption, and result in robust, compact, cost effective device with high accuracy for mechanical and electrical systems. 
       SUMMARY 
       [0006]    Some embodiments provide a motion control system controlling an image projected from an underwater projection system in a water feature, pool, or spa. The system includes a rotatable base and a mirror support member hingedly coupled to the rotatable base. A first motor is coupled to the rotatable base and is configured to rotate the mirror support member in a first plane. A second motor is coupled to the rotatable base and a fixed mount, wherein the second motor is configured to rotate the rotatable base relative to the fixed mount thereby rotating the mirror support member in a second plane. 
         [0007]    Some embodiments provide a motion control system controlling an image projected from an underwater projection system in a water feature, pool, or spa. The system includes a projector for displaying the image, a first motor coupled to a first cam, and a second motor coupled to a second cam. A mirror support member is configured to move about a first moment in a first direction and about a second moment in a second direction. Movement in the first direction is imparted by the first motor rotating the first cam, and movement in the second direction is imparted by the second motor rotating the second cam. The first cam imparts motion directly to the mirror support member and the second cam imparts motion to the mirror support member indirectly through moving the second motor relative to a fixed mount. 
         [0008]    Some embodiments provide an underwater projection system for a water feature. The system includes a projector designed to display an image in the water feature. The system further includes a motion control system having a base, a mirror hingedly coupled to the base, a first motor coupled to the base and configured to rotate the mirror in a first direction, and a second motor coupled to the base and a fixed mount, wherein the second motor is configured to rotate the base and thereby rotate the mirror in a second direction. A controller is configured to steer the image from the projector that is reflected off the mirror of the motion control system within a defined boundary space within the water feature by controlling the motion control system. 
         [0009]    Moreover, the above objects and advantages of the invention are illustrative, and not exhaustive, of those which can be achieved by the invention. Thus, these and other objects and advantages of the invention will be apparent from the description herein, both as embodied herein and as modified in view of any variations which will be apparent to those skilled in the art. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Embodiments of the invention are explained in greater detail by way of the drawings, where the same reference numerals refer to the same features. 
           [0011]      FIG. 1  shows an isometric view of the rotary motion system and driver; 
           [0012]      FIG. 2  shows a further isometric view of the rotary motion control system and drive of  FIG. 1 ; 
           [0013]      FIG. 3  shows an isometric view of the second drive shaft of the exemplary embodiment of  FIG. 2 ; 
           [0014]      FIG. 4  shows an isometric view of the first drive shaft coupled to the support shaft of  FIG. 2 ; 
           [0015]      FIG. 5  provides a further isometric view of the first drive shaft coupled to the mirror support of  FIG. 4  with relative motion indicated; 
           [0016]      FIG. 6  shows a plan view for a controller for the exemplary embodiment of  FIG. 1 ; 
           [0017]      FIGS. 7A-7D  show various shapes and configurations of mirrors and optics that may also be used in conjunction with the exemplary embodiments of the invention; 
           [0018]      FIGS. 8A-8C  show isometric left, right, and bottom views of a further exemplary embodiment of the rotary motion control system; 
           [0019]      FIG. 9  shows an isometric view of the chassis of the exemplary embodiment of  FIGS. 8A-C ; and 
           [0020]      FIGS. 10A and 10B  show the pivot member of the exemplary embodiment of  FIGS. 8A-C  with the support member. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]      FIG. 1  shows an isometric view of the rotary motion control system and driver. The system includes a mounting element  310  coupled to and output or support shaft  320  through a two-axis coupling generally shown as  400 ,  500  having at least two input shafts  420 ,  520  which are in turn coupled to at least two drive mechanisms  110 , 120 , respectively. In this exemplary embodiment shown, the at least two drive mechanisms  110 ,  120  are shown as electromagnetic drive mechanisms  110 ,  120 . These can be mechanically, magnetically or electromechanically coupled to the at least two input shafts  420 ,  520  as best shown in  FIG. 2 . The two electromagnetic drive mechanisms  110 ,  120  are coupled to a chassis  200 . The chassis serves to hold the motors stationary at a required position and angle. The angle in the embodiment is 90 degrees but other angles could also be employed without departing from the spirit of the invention. In  FIG. 1 , drive mechanisms  110  and  120  represent an electric motor. Some non-limiting examples of further mechanical driving systems include but are certainly not limited to galvanometers, stepper motors, motors with gears or transmissions, and the like. Modifications can be made to the driving source without departing from the spirit of the invention. 
         [0022]      FIG. 2  shows a further isometric view of the rotator motion control system and drive of  FIG. 1 . In this figure, the drive mechanisms  110 ,  120  have been omitted to more clearly see the workings of the embodiment.  FIG. 2  provides a clearer view of the two-axis coupling members  400 ,  500 . As shown in  FIG. 2 , at least two indexing blades  430 ,  530  are provided to index the at least two input shafts  420 ,  520 , here shown as a first input shaft  520  and a second input shaft  420 , which are driven from drive shafts  410 ,  510  coupled to the input shafts  420 ,  520  and drive members. The drive members may be electrical motors, magnetic drives, piezo drives, mechanical drives, or similar devices, as noted above. 
         [0023]    The drive mechanisms  110 ,  120  move drive shafts  410  and  510  which impart movement in the input shafts  420 ,  520 , respectively. The drive shafts  410 ,  510  allow rotary torque from drive mechanisms  110 ,  120  to be transmitted to the coupling members  400 ,  500 . The coupling is created in this exemplary embodiment through keying the drive shafts  410 ,  510  within the input shafts  420 , 520 . In further exemplary embodiments the drive and input shafts may be a single component. These points of coupling in the exemplary embodiment of  FIG. 2  are keyed to prevent slippage between the drive shaft  410 , 510  and input shaft  420 , 520 . The coupling of the drive shafts  410 , 510  may allow for a screw or other fastening device to be used that allows for parts to be connected to them. Each blade is coupled to the controller through optical sensors  440 ,  540  which, in conjunction with a controller  700  index the position of the at least two indexing blades  430 , 530  and thereby the position of the input shafts  420 ,  520 . 
         [0024]    In the exemplary embodiment shown, the sensors are, as a non-limiting example, opto-interrupter type sensors. In further exemplary embodiments, other sensors can be used, for instance but certainly not limited to, Hall Effect sensors, potentiometers, capacitive sensors, and the like. The sensor type shown in the exemplary embodiment allows for the edges of the indexing blades  430 ,  530  to be detected which in turn allows for detection of an absolute position for the arms. Alternately, in one of the further exemplary embodiments for instance, one can use Hall Effect sensors, capacitive sensors or potentiometers to provide a linear or multi-point signal to identify the position directly. In further exemplary embodiments, one can couple the sensors to a different part of the drive mechanism, such as the other side of the motor, or to any part of the gearbox, that can allow a controller to track the relative motion and relate this to the pitch and yaw translation of the reflected image or radiation without departing from the spirit of the invention. 
         [0025]    The first coupling member  500  is linked to an at least one support shaft  320  and the second input shaft  520  guides the support shaft  320  in an at least one channel member  445  to facilitate controlled motion of the mounting element  310 . The motion of input shafts  420 ,  520  are transferred through the linkage  545  or the channel member  445  which in turn propel and guide the at least one support shaft  320 . The at least one support shaft  320  passes through the channel  450  and is coupled to the coupling member  500  by an at least one input coupling or linkage  545  which is coupled to and drives the at least one support shaft  320 . Although a single support shaft  320 , a single channeled member  445 , and a single drive or input coupling  545  are provided, additional elements or members may be utilized without departing from the spirit of the invention. In the exemplary embodiment shown, the at least one input coupling  545  fits within a curved portion of the at least one channeled member  445 , the at least one support drive or input coupling  545 . The at least one support shaft  320  supports an at least one mount element or base  310 . The exemplary embodiment shows a mirror coupled to the at least one mount element or base  310  and the mount element or base  310  being directly secured to the driven support shaft  320 . However, several different techniques to attach the at least one mount element or base  310  to the support shaft  320 , for instance variations can be provided to aid in the manufacturability and durability of the product. Some non-limiting examples of alternate mechanisms for coupling the driven shaft can include designing the mirror to be inserted into a socket or cavity to ensure accurate positioning of the mirror without departing from the spirit of the invention. The surface that is moved by the driven shaft may also be secured to the shaft using a screw or other fastening mechanism or similar mechanisms. The exemplary embodiment shown uses a flat mirror, however, several different shapes of mirrors and optics are contemplated, as further seen in  FIGS. 7A through 7D  and described herein below. 
         [0026]    The at least two drive mechanisms  110 ,  120  input motion through an at least two drive shafts or couplings  410 ,  510  which in turn move the at least two input shafts  420 ,  520  respectively. The at least two input shafts  420 ,  520  turn and input or indexing blades  430 ,  530  measures the degree of this movement and with the controller  700  control this movement. The at least two input shafts  420 ,  520  are coupled to one another and the at least one support shaft  320  through input coupling  545  which extends from input shaft  520  and is coupled through the input coupling  545  to the support shaft or member  320  and the channel  450  in input shaft  420  through which the support shaft  320  passes. In this fashion the rotation of the drive shafts  410 ,  510  is translated into motion of the respective at least two input shafts  420 ,  520 . This motion in turn moves input shaft  520  and support shaft or member  320  about the axis of pin  600  which guides support member or shaft  320  within the channel  450 . By sliding within channel  450  and about the hinge created by pin  600  the pitch and yaw of support shaft  320  is achieved. 
         [0027]    The sliding and motion of the two axis coupling can be further aided by adding lubrication to the moving parts and the channel. The lubricant may be of any typical type, including but not limited to an oil, silicone, mineral, or similar lubricant which can be applied or contained in a bath to adhere to the moving parts of the coupling members  400 ,  500  of the two axis coupling to allow for free and smooth low friction motion. Additionally, the fabrication of members  300 ,  400 , and  500  may include low friction wear surfaces which come in contact with other moving members using low friction materials such as a high performance polymer, such as but certainly not limited to Polyoxymethylene (POM), Polyetheretherketone (PEEK), Polyimide (PI), Polyamide (PA), Ultra High Molecular Weight Polyethylene (UHMWPE) or Polyethylene Terephthalate (PET) as non-limiting examples. These materials can be used to fabricate the entirety of the component or the wear surfaces. The components in the exemplary embodiment are as a nonlimiting example fabricated completely from POM. Additional embodiments can utilize a metal, such as but certainly not limited to anodized aluminum, stainless steel, or a composite material such as a reinforced graphite or high performance polymer impregnated with a composite material, or similar compounds in the fabrication of the device to minimize wear and friction. 
         [0028]      FIG. 3  shows an isometric view of the second input shaft of the exemplary embodiment of  FIG. 2 . As shown in the figure, an indexing blade  430  is shown with an input shaft  420  coupled thereto. A curved section  441  of the channeled member  445  is provided and the channel  450  in the channel member  445  is shown therein. The channel  450  is created so that the at least one support shaft or member  320  can glide through it when propelled by the second input shaft  420 . However it is the second indexing blade  430  that controls the position of the at least one mount element  310  in the secondary axis. 
         [0029]      FIG. 4  shows an isometric view of the first input shaft coupled to the mirror support of  FIG. 2 . As shown first support shaft  520  is coupled to the mirror support  320  through input coupling  545 . A central drive shaft  510  is located within the first support shaft  520 . As shown, this is a joint coupling with a pin member  600 , the joint coupling permitting two-axis motion of the mirror base  310  through the mirror support  320 , as better descried in  FIG. 5 . The second support member  420  restrains and guides the motion imparted by the first support member  520  allows for pan-yaw motion of the at least one mirror base  310 . The pin  600  may also be but is certainly not limited to a screw, a rivet, a standoff bolt or the like. The design of the hinge member or input coupling  545  may allow a screw to secure drive shaft  510  to input shaft  520 , permitting only one axis of motion. Various approaches may be used to serve the function of pin  600  without departing from the spirit of the invention. 
         [0030]      FIG. 5  provides a further isometric view of the first input shaft coupled to the mirror support of  FIG. 4  with relative motion indicated.  FIG. 5  highlights the two axis of motion available to the first input shaft  520 . A driven motion turns the input shaft  520 , as shown by the arrow, in a direction based on motion imparted on the index blade  530 . This can be imparted electromagnetically, as would be provided by a galvanometer or electromagnetic motor or the like, or through mechanical means, such as but not limited to a stepper motor or worm gear motor or the like. The relative motion of the blade  530  is translated very accurately to motion in the input shaft  520 . The input shaft in turn turns as indicated. In addition, through the pinned joint of input coupling  545 , mirror support shaft  320  is free to pivot about the pin  600  in the input coupling  545 . This axis of motion is restrained by the channel  450  of the first input shaft and its channel member  445 . As noted above, in this fashion the motion of the mirror support  310  is accomplished and controlled. 
         [0031]      FIG. 6  shows a plan view for a controller for the exemplary embodiment of  FIG. 1 . The controller  700  is coupled to or contains a Rotary Motion Control System and Driver Circuit. It provides a module for calibration  750  of the system and a separate module for pan and yaw correction  760 , as shown. The circuit includes sensors  440 , in this case opto-isolator sensors as discussed further herein below,  440 ,  540  as seen in  FIG. 2  in the system providing position feedback for the first axis of motion (Axis A) and second axis of motion (Axis B) relative to the at least two drive mechanism alone or in conjunction with the indexing blades. Relative positions of the at least two indexing blades  430 ,  530  are related to the position of the system in the calibration module. The pan and yaw correction module takes programmed corrections provided during or after operations and translates this to relative X axis and Y axis outputs  730 ,  740  respectively. 
         [0032]    One non-limiting example of an application of the exemplary embodiment of the instant invention as shown and described herein is as the rotary motion control system and driver circuit as a component of an underwater projection system secondary steering mechanism used in conjunction with an underwater DLP projection system. The second mirror functions to move reflected images from the underwater DLP projection system within a defined boundary space within a water feature such as, but not limited, to a pool as described in Applicant&#39;s co-pending U.S. patent application Ser. No. 13/533,966, filed Jun. 26, 2012. The controller  700  may be a controller for such an underwater projection system or a further controller or a separate controller communicating with the controller  700  and the modules discussed above. 
         [0033]      FIGS. 7A-7D  show various shapes of mirror elements that may alternatively be used in conjunction with the exemplary embodiment of  FIG. 1 . In addition to the flat mirror base  310  shown in  FIGS. 1-6 ,  FIGS. 7A-7D  show various shapes and configurations of mirrors and optics that may also be used in conjunction with the exemplary embodiment. These embodiments are non-limiting examples and are provided to show the breadth of the utility of the invention as a beam steering device.  FIG. 7A  represents a multifaceted mirror or optic  360 , having several reflective planes and coupled to a shortened mirror support  320  and coupling  330  that receives the pin  600  as identified above.  FIG. 7B  shows a divergent mirror  350  with a generally convex shape similar to a surface portion of a sphere coupled to the mirror support  320  and the coupling  330 .  FIG. 7C  shows a flat mirror element  310  with an angled attachment point  770  at the attachment point of the mirror support  320  and coupling  330 .  FIG. 7  D shows an offset attachment point for a flat mirror base  310  with mirror support  320  not attaching at the center of the mirror base  310  but at an offset point and having the mirror support  320  extend from there to the coupling  330 . In addition, the support shaft  320  and mount element  310  can attach other elements such as optics, optical modulations, diffraction gratings, reflective surfaces and the like. 
         [0034]      FIGS. 8A-8C  show isometric left, isometric right, and isometric bottom views of a further exemplary embodiment of the rotary motion control system. The system moves a mirror member  310  on a mirror support  320 . A chassis or body member  200  has an at least one motor, shown as a first motor  110  for imparting vertical or up-down motions in the mirror element  310  and a second motor  120  imparting horizontal or side to side motion as described herein below. 
         [0035]    As see in  FIG. 8A  an at least one vertical cam  415  is coupled to the first or vertical drive moor  110 . The cam  415  is coupled to a attachment point  312  that extends from the mirror support  320 . The attachment point  312  is connected to the vertical cam  415  through a first of an at least two drive shafts or linkages, here vertical linkage  4100 . A similar second of an at least two drive shafts or linkages is shown in  FIGS. 8A-9  as horizontal linkage  5100 . Additional shafts, input shafts, or linkages may be used to couple the respective at least one cams to the mirror element and impart relative motion. The vertical linkage is also in communication with an at least one sensor, here shown as vertical sensor  440  mounted on a sensor support  442 . The sensor  440  determines the condition of the movement imparted to the mirror element  310  by the linkage  4100 . In this instance the at least one sensor also includes a horizontal movement sensor  540  and a bracket or support member  542  in communication with the horizontal linkage. The horizontal movement as described herein below in relation to  FIGS. 8B-10B  is also thereby tracked. 
         [0036]    The motion produced by the at least one vertical cam  415  through the linkage  4100  provides a moment of movement about a hinge  215  and hinge pin  212 , as better seen in relation to  FIGS. 8B and 9 . The movement is about the axis of the hinge pin  212  and is shown in the figure with the aid of arrows as relative motion A. The hinge  215  acts as a first restraint mechanism permitting the motion indicated. 
         [0037]      FIG. 8B  shows an isometric view from the side of the device opposite that of  8 A. The hinge  215  and hinge pin  212  are more clearly seen in relation to the mirror support  320 . The at least one motor, here vertical motor  110  and horizontal motor  120 , are also shown. A fixed mount  517  exists apart from the chassis  210 . The mount secures a ball and socket joint acting as a coupling to the second of an at least two drive shafts or linkages, here the horizontal linkage  5100 . The horizontal linkage  5100  is coupled by a further ball and socket coupling mechanism at an opposite end of the horizontal linkage  5100  to a further at least one cam, here horizontal cam  515 . The horizontal cam  515  is coupled to the drive motor  120  and acts to move the chassis  210  about the ends of the horizontal linkage  5100 . As noted above, a horizontal sensor  540  and support member or bracket  542  engage a sensor element  432  to determine horizontal movement. 
         [0038]    The motion of the horizontal cam  515  moves the coupling with the at least one horizontal linkage  5100 . The other end of the linkage being fixed to the fixed mount  517 , the motion is restrained and the relative distance between the coupling points fixed. The circular motion of the horizontal cam results in a twisting moment about the chassis  210  relative to  FIG. 8B  shown in the figures by movement arrow B. This twisting moment is the horizontal movement as the device on a pivot point  257 , the fixed coupling acting as a second further restraining mechanism, as further shown and described in relation to  FIG. 8C . 
         [0039]      FIG. 8C  shows a bottom view of the exemplary embodiment of  FIGS. 8A-8B . A pivot member  250  is provided passing through an element of the chassis as best seen in  FIG. 9 . The pivot member  250  includes a pivot member support body  255  and the support body has or acts as a low friction spacer. The pivot member  250  with its pivot pin  257  allows for movement as indicated by movement arrow B, about the axis of the pivot pin  257 . This is imparted by the translation of the horizontal cam  515  imparting motion through the couplings to the horizontal linkage  5100 . As noted previously a sensor  540  and bracket  542  are provided to sense the horizontal disposition of the device. 
         [0040]      FIG. 9  shows a further isometric view of the chassis of the exemplary embodiment of  FIGS. 8A-8B . As more clearly seen in this view the hinge  215  and pivot pin member hole  251  are clearly seen. It is about the axis of these two elements the chassis is moved to import both pitch and yaw or vertical and horizontal motion in the mirror element  310 . In the case of the up-down or vertical motion provided by the vertical linkage  4100 , the hinge  215  and hinge pin or member  212  restrain the devices relative motion. Further, the inset nature of the pivot member prevents unbridled movement and limits the motion imparted to rotation about an axis, namely the axis of the pivot pin  257 . As best shown by the arrows showing relative motion. 
         [0041]      FIG. 10A and 10B  show the pivot member  250  of the exemplary embodiment of  FIGS. 8A-C  with the pivot member support body  255 . The pivot member  250  includes the pivot pin  257 . The pivot pin  257  is oriented such that the chassis  210  rests atop of it. It is held by the pivot member support body  255 . The pivot member support body  255  passes through the pivot member hole  251 . The pivot pin  257  is in contact with the pivot member support body  255 . The pivot member support body  255  is provided with a slot  810  which corresponds to a groove  825  on the pivot pin  257 . The pivot pin  257  is slidingly coupled to the pivot member support body  255 . This is one example of providing the pivot pin  257 , further variations in the exact members may be provided such that a pivot pin  257  supports the chassis  210  and allows for the movement indicated. 
         [0042]    Thus through the at least one cam, here horizontal and vertical cams, coupled to the mirror support member  320  through an at least two linkages and restrained by a hinge member and a pivot member, the mirror element  310  is provided both vertical or up down movement as well as horizontal or side to side movement in the further embodiment. 
         [0043]    The embodiments and examples discussed herein are non-limiting examples. The invention is described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the claims is intended to cover all such changes and modifications as fall within the true spirit of the invention.