Abstract: A method of assembling components of an assembly, such as the components of a truss, using a laser imaging system in combination with assembly jigs. The jigs may be slidably mounted on an assembly table wherein the jigs include laser alignment indicia on a top surface of the jigs spaced a predetermined distance from a side surface of the jigs. The method includes projecting an enlarged laser generated outline of at least a portion of the components to be assembled which is spaced laterally from an outline or template of the components in the assembled position a distance equal to the distance between the laser alignment indicia and the side surface of the jigs and spaced vertically a distance equal to the distance between the indicia and the work surface. The jigs are then moved on the work surface to align the laser alignment indicia with the enlarged outline and affixed relative to the work surface.

Abstract: A laser scanning method and system for determining an outline of an object. A laser beam is projected at the object and a surface underlying the object. The surface is configured to reflect the laser beam differently than the object. The laser beam is reflected off the object and the surface producing reflected beams. The reflected beams are received by a control which determines whether the beam was reflected from the object or the surface. By identifying this with the laser position the control can identify the part outline. As the laser beam is scanned over successive positions along the surface, the outline of the object is precisely determined.

Abstract: An improved laser projector collimator includes a plurality of specifically designed and arranged mirrors and lenses such that reflected light from a housing window for the laser projector is not directed onto a reflected light source sensor. In this way, the sensor only sees light reflected from a reference reflector. In addition, the specific arrangement of the lenses and mirrors is such that the overall length of the collimator housing is greatly reduced.

Abstract: An improved method and apparatus for controlling a laser projection assisted assembly operation includes the ability to display a menu with the laser projector. An operator is able to request the menu be displayed at the operator's location. The menu provides the operator the ability to select from several display options. By selecting an icon associated with a desired display option, the operator is able to change the display option at a location remote from the control. This is particularly valuable in large laser assisted work assemblies.

Abstract: A laser scanning method and system for determining an outline of an object. A laser beam is projected at the object and a surface underlying the object. The surface is configured to reflect the laser beam differently than the object. The laser beam is reflected off the object and the surface producing reflected beams. The reflected beams are received by a control which determines whether the beam was reflected from the object or the surface. By identifying this with the laser position the control can identify the part outline. As the laser beam is scanned over successive positions along the surface, the outline of the object is precisely determined. In a preferred embodiment, the laser scanning system further includes a transparent support for supporting the object a predetermined distance from the surface thereby increasing the scanning resolution and improving the accuracy of the system.

Abstract: An improved method and apparatus for controlling a laser projection assisted assembly operation includes the ability to display a menu with the laser projector. An operator is able to request the menu be displayed at the operator's location. The menu provides the operator the ability to select from several display options. By selecting an icon associated with a desired display option, the operator is able to change the display option at a location remote from the control. This is particularly valuable in large laser assisted work assemblies.

Abstract: A 3D vision system utilizes a CCD camera to first generate a two dimensional image of the object. A computer analyzes the two dimensional image to determine areas of interest, such as high contrast areas which indicate sharp discontinuities. A laser range scanner, controlled by the computer, then scans the object at a variable resolution, increasing its resolution in the areas of interest to generate a computer model.