Abstract: A method of identifying an item on a surface of a workpiece is disclosed. An optical device identifies an item on the surface of a workpiece. An item identification system includes a light projector and a photogrammetry system. One of the light projector and the photogrammetry system generates a three-dimensional coordinate system within the work cell. One of the light projector and the photogrammetry system identifies a location of the surface of the workpiece within the three-dimensional coordinates system. The controller calculates geometric location of the item on the surface of the work piece in the three-dimensional coordinate system as identified by the optical device. The controller signals the light projector to project a beam of light onto the surface of the workpiece identifying a disposition of the item disposed upon the surface of the workpiece.

Abstract: A system and method for aligning projection of an optical indicia on a surface of a large object is disclosed. A reference is disposed in proximity to the object. The reference includes a plurality of markers spaced at intermittent locations. A projection system projects optical indicia onto the surface of the object. A detection system detects the markers disposed upon the reference and signals an image of the markers to a processor for the processor to register a location of the projection system relative to the reference. The reference is aligned with a feature disposed upon the object enabling registration of the markers to the object. A location of the projection system relative to the object is established enabling the projection system to project the optical indicia onto the object to a predetermined location.

Abstract: A system identifying an area of interest of an inspection surface is disclosed. A controller includes a machine learning model trained using stored images defining an area of interest on the inspection surface. A laser projector for projecting laser indicia onto the inspection surface is spatially located relative to the inspection surface enabling the laser projector to project the laser indicia onto the area of interest. An imager includes an image sensor system generates a current image of the inspection surface and signals the current image to the controller. The machine learning model is directed to the area of interest of the current image as identified by the laser indicia and the machine learning model implementing the neural network to inspect the current image of the area of interest as defined by the laser indicia enabling localized inspection of the inspection surface.

Abstract: A system for identifying accurate assembly of a component to a workpiece is disclosed. The system includes a light source for projecting light indicia onto the component assembled to the workpiece. A controller includes an artificial intelligence (AI) element defining a machine learning model that establishes a convoluted neural network trained by stored images of light indicia projected onto the component assembled to the workpiece. An imager includes an image sensor system for imaging the workpiece and signaling a current image of the workpiece to the controller. The machine learning model directs inspection of the workpiece to the light indicia imaged by said imager. The AI element determines disposition of the component disposed upon the workpiece through the neural network identifying distortions of the light indicia in the current image.

Abstract: A method and system for controlling projection of optical indicators on a worksurface is disclosed. A projection device for projecting a first optical indicator and a second optical indicator onto a worksurface is provided. A measurement system monitors a work area in which the worksurface is disposed. The measurement system locates a control object within the work area and identifies a marker disposed on the control object. The measurement system monitors a first disposition and a second disposition of the control object. The projection device projects the first optical indicator onto the worksurface and the projection device projects the second optical indicator onto the worksurface in response to manipulation of the control object between the first disposition and the second disposition as detected by said measurement system.

Abstract: A method for validating the placement of pieces in an assembly task by scanning a coherent light source, such as a laser, over a surface and characterizing the detected interference speckle pattern to discriminate the position of the placed piece from the surface on which the piece is placed. This discrimination is possible even if the characteristic features of the piece and background are smaller than the resolution of the scanning system. In addition, characteristics of the piece, such as the orientation of fibers in the material, may be sensed by classification of the associated speckle response.

Abstract: A system and method for aligning projection of an optical indicia on a surface of a large object is disclosed. A reference is disposed in proximity to the object. The reference includes a plurality of markers spaced at intermittent locations. A projection system projects optical indicia onto the surface of the object. A detection system detects the markers disposed upon the reference and signals an image of the markers to a processor for the processor to register a location of the projection system relative to the reference. The reference is aligned with a feature disposed upon the object enabling registration of the markers to the object. A location of the projection system relative to the object is established enabling the projection system to project the optical indicia onto the object to a predetermined location.

Abstract: A first projection device includes a first laser projector and a first measurement system. A second projection device includes a second laser projector and a second measurement system. The first projection device and the second projection device is interconnected with a controller. The controller is programmed with computer aided design data representative of a large scale work area and coordinates electronic interaction between the first projection device and the second projection device. The first projection device projects a first indicia that is detectable by the second measurement system and the second projection device projects a second indicia that is detectable by the first measurement system. The controller is adapted for determining relative position within three-dimensional coordinate system of the first projection device to the second projection device from the first indicia detected by the second measurement system and the second indicia detected by the first measurement system.

Abstract: A laser projection system for projecting laser image onto a work surface providing optimized laser energy includes laser source and an electronic circuit for modulating an output power level. A galvanometer assembly includes a scanning mirror operated a mirror control circuit for redirecting the laser beam onto the work surface along a scanning path for generating the laser image. The galvanometer assembly is electronically connected to the electronic circuit for signaling an angular velocity of the scanning mirror to the electronic circuit. A controller includes a scanning path input module for generating a simulation of the angular velocity of the scanning mirror along the scanning path for estimating a concentration of laser energy along areas of the scanning path of the laser beam. The electronic circuit modulates energy concentration of the laser beam in response to the estimated concentration of laser energy and the angular velocity of the scanning mirror.

Abstract: A method of verifying placement of a piece on a work surface is disclosed. An imaging device and an illumination system are electronically interconnected with a computer. The illumination system projects indicia onto a work surface for indicating a location for placement of a piece on the work surface. An indicator is provided to the piece that includes light emission displaying fluorescent wavelengths when illuminated for distinguishing the piece form the work surface. The piece is placed upon the work surface at a location indicated by the laser indicia. The illumination system illuminates the piece presenting a visible contrast between the piece and the work surface enabling the imaging device to distinguish the piece from the work surface. The imaging device signals the controller a location of the piece for the controller to verify accurate placement of the piece.

Abstract: A camera assembly for generating a high resolution image of an area of interest on a workpiece includes a sensor array and an optical lens that focuses light reflected from the workpiece onto the sensor array. The sensor array is inclined relative to an optical axis defined by the optical lens disposed in a fixed position relative to the optical lens. A galvanometer driven mirror assembly directs a field of view of the optical lens toward the area of interest on the workpiece translating light reflected from the area of interest of the workpiece onto the sensor array. The inclination of the sensor array provides varying degrees of resolution relative to a distance of the workpiece area of interest from the camera assembly enabling the camera assembly to generate high resolution images at varying distances from the camera assembly without adjusting the optical lens relative to the sensor array.

Abstract: A method of projecting a template on a workpiece provides a measurement system for determining a location of a workpiece and a laser projector for projecting a laser template. A feature on the workpiece having geometric significance is identified. A physical location of the feature in a three dimensional coordinate system is determined and compared to a theoretical location of the feature on computer model of the workpiece. A template correlated to the feature is selected. The projection of the template onto the workpiece relative to the feature is optimized by correlating alignment of the physical location of the feature with the computer model of the feature. The template is projected onto the workpiece based upon the optimized projection for directing work to be performed on the workpiece.

Abstract: A laser projection system for projecting an image on a workpiece includes a photogrammetry assembly and a laser projector, each communicating with a computer. The photogrammetry assembly includes a first camera for scanning the workpiece, and the laser projector projects a laser image to arbitrary locations. Light is conveyed from the direction of the workpiece to the photogrammetry assembly. The photogrammetry assembly signals the coordinates light conveyed toward the photogrammetry assembly to the computer with the computer being programmable for determining a geometric location of the laser image. The computer establishes a geometric correlation between the photogrammetry assembly, the laser projector, and the workpiece for realigning the laser image to a corrected geometric location relative to the workpiece.

Abstract: A camera assembly for generating a high resolution image of an area of interest on a workpiece includes a sensor array and an optical lens that focuses light reflected from the workpiece onto the sensor array. The sensor array is inclined relative to an optical axis defined by the optical lens disposed in a fixed position relative to the optical lens. A galvanometer driven minor assembly directs a field of view of the optical lens toward the area of interest on the workpiece translating light reflected from the area of interest of the workpiece onto the sensor array. The inclination of the sensor array provides varying degrees of resolution relative to a distance of the workpiece area of interest from the camera assembly enabling the camera assembly to generate high resolution images at varying distances from the camera assembly without adjusting the optical lens relative to the sensor array.

Abstract: A method of accurately projecting a laser image pattern on a work surface and continuously compensating for relative dynamic movement between the laser and the work surface, including establishing a position of the camera in three dimensions relative to the work surface by locating the targets in the camera image, establishing a position of the laser relative to the work surface utilizing the fixed position of the laser relative to the camera, and using a computer to continuously adjust the rotation of the laser projector mirrors in response to dynamic movement of the laser projector relative to the work surface as determined by the camera. In one embodiment, the computer continuously tracks at least two prior locations of the laser projector relative to the work surface and predicts the next location of the laser, compensating for movement of the laser relative to the work surface.

Abstract: A method of projecting a template on a workpiece provides a measurement system for determining a location of a workpiece and a laser projector for projecting a laser template. A feature on the workpiece having geometric significance is identified. A physical location of the feature in a three dimensional coordinate system is determined and compared to a theoretical location of the feature on computer model of the workpiece. A template correlated to the feature is selected. The projection of the template onto the workpiece relative to the feature is optimized by correlating alignment of the physical location of the feature with the computer model of the feature. The template is projected onto the workpiece based upon the optimized projection for directing work to be performed on the workpiece.

Abstract: A laser projection system for projecting an image on a workpiece includes a photogrammetry assembly and a laser projector, each communicating with a computer. The photogrammetry assembly includes a first camera for scanning the workpiece, and the laser projector projects a laser image to arbitrary locations. Light is conveyed from the direction of the workpiece to the photogrammetry assembly. The photogrammetry assembly signals the coordinates light conveyed toward the photogrammetry assembly to the computer with the computer being programmable for determining a geometric location of the laser image. The computer establishes a geometric correlation between the photogrammetry assembly, the laser projector, and the workpiece for realigning the laser image to a corrected geometric location relative to the workpiece.

Abstract: A laser projector including a green diode pumped microchip laser module projecting a green laser beam, an optical sensor receiving the laser beam, a power control circuit for the green diode pumped microchip laser module receiving a signal from the optical sensor relative to the power output of the laser beam, and control electronics receiving the signal from the optical sensor connected to the power control circuit modulating the power output of the green diode pumped microchip laser module to maintain a substantially constant power output from the green diode pumped microchip laser module.

Abstract: An assembly apparatus for assembling components including a work surface, a laser projector, a computer controlling the laser projector to protect a laser image on the work surface, and an ejector lifting a completed assembly from the work surface having a retro-reflective surface within a field of view of the laser projector when the ejector is lifted, such that the laser projector scans the retro-reflective surface and the computer determines at least one of the number of completed assemblies made and the time required to make the assembly.

Abstract: A laser projector system includes a computer and a laser projector for projecting a laser image on a target surface, particularly in a factory or manufacturing environment. The computer is disposed remote from the laser project and provides the laser projector with a command and control signal. Communication between the computer and the laser projector is accomplished with power line network adapters. These adapters modulate an AC waveform to encode the command and control signal and other data. Thus, communication between the computer and the laser projector is accomplished without need for long runs of communication cables.