Abstract: A method of identifying an accurate assembly of a component onto a workpiece to an operator includes the use of a laser projector and a headset or goggles. The laser projector projects laser images relative to the workpiece. The headset or goggles includes an imaging device and a display element. A location of the laser projector, the imaging device and the display element is registered in a common coordinate system relative to the workpiece. The imaging device generates an image of a view of the workpiece appearing in the display element when viewed by the operator though the display element. A computer generated image of the component is overlaid upon the image of the workpiece being disposed in a geometrically accurate location on the image of the workpiece. The image of the workpiece appearing in the display element is registered to the three dimensional coordinate system defined relative to the workpiece.

Abstract: A method of detecting a presence of foreign material in a ply is disclosed. A source of foreign material is marked with a fluorescent indicator. The source of foreign material is separated from the ply. An illumination source is provided for illuminating the ply at a different wavelength than the fluorescent indicator fluoresces so that the ply reflects light at a different wavelength. A sensor detects illumination of the ply and fluorescent indicator included in the foreign material disposed upon the ply. Differences in light reflected from the ply and fluorescence of the indicator disposed in the foreign material are detected thereby identifying existence of the foreign material in the ply.

Abstract: A method for detecting inconsistencies in an assembly using an energy source and an imaging device is disclosed. An energy source directs energy through first scanning mirrors toward a surface of the laminated composite assembly raising an energy level of an inspection area. An imaging device directs a view through second scanning mirrors toward the inspection area and the imaging device detects a rate of change in energy at the surface of the laminated composite. Movement of the first scanning mirrors is synchronized with movement of the second scanning mirrors for directing a view of the imaging device to the inspection area after the energy level of the area of the surface has been raised. The imaging device detects dissipation of energy at the area of the surface being inspected and identifies inconsistencies associated defects in the assembly.

Abstract: A method of identifying accurate location of a component onto a workpiece is disclosed. A laser projector projects laser images relative to the workpiece. An imaging device generates a video image and a display device displays the video image from a view of the imaging device. The display device generates a video image from a view of the workpiece by the imaging device. The laser projector projects a plurality of laser images relative to the workpiece and the display device registers the view of the imaging device relative to the workpiece from the plurality of laser images. The display device generates a virtual image of the component upon the video image of workpiece. The virtual image of the component disposed in a geometrically accurate location upon the video image of the workpiece.

Abstract: A rotary stage assembly includes a platform and a rotary drive defining an axis of rotation. The platform is mounted on a spindle for receiving rotary movement from the rotary drive. A cylindrical wall is attached to the platform receiving rotary movement from the rotary drive and is coaxial with the axis of rotation defined by the rotary drive. The cylindrical wall defines an inner surface including reference patterns. An imaging assembly images the reference patterns on the inner surface of the cylindrical wall. The imaging assembly detects angular orientation and tilt of the platform from an axis of rotation of the platform from imaging the reference patterns on the inner surface of the cylindrical wall. A controller calculates angular orientation and tilt of the platform from the location of said reference patterns signaled from the imaging assembly.

Abstract: A laser projector assembly for projecting a template onto an object is provided. The laser projector assembly includes a frame, a laser source for generating a laser beam being affixed to said frame, a sensor assembly, a lens assembly and a galvanometer assembly. The sensor assembly is affixed to said frame for identifying surface locations of three dimensional objects. The lens assembly includes a tunable lens for changing a focus of the laser beam received from said laser source. The galvanometer assembly redirects the laser beam received from said lens assembly along a scanning path. The lens is disposed in a fixed location relative to said sensor assembly and is tunable in response to the surface locations of the three dimensional objects identified along the scanning path of the laser beam by said sensor assembly.

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 method for aligning a laser projector for projecting a laser image onto a work surface is provided. The method includes providing a laser projector assembly with a laser source for projecting a laser image onto a work surface, a secondary light source for illuminating the work surface and a photogrammetry device for generating an image of the work surface. The method also includes affixing reflective targets onto the work surface and transmitting light from the secondary light source toward the work surface and reflecting light toward the photogrammetry device. The method further includes scanning the targets with a laser beam generated by the laser source for reflecting the laser beam toward a laser sensor and calculating a location for projecting the laser image onto the work surface from the reflected laser beam.

Abstract: A method for aligning a laser projector for projecting a laser image onto a work surface is provided. The method includes providing a laser projector assembly with a laser source for projecting a laser image onto a work surface, a secondary light source for illuminating the work surface and a photogrammetry device for generating an image of the work surface. The method also includes affixing reflective targets onto the work surface and transmitting light from the secondary light source toward the work surface and reflecting light toward the photogrammetry device. The method further includes scanning the targets with a laser beam generated by the laser source for reflecting the laser beam toward a laser sensor and calculating a location for projecting the laser image onto the work surface from the reflected laser beam.

Abstract: A method for aligning a laser projector for projecting a laser image onto a work surface is provided. The method includes providing a laser projector assembly with a laser source for projecting a laser image onto a work surface, a secondary light source for illuminating the work surface and a photogrammetry device for generating an image of the work surface. The method also includes affixing reflective targets onto the work surface and transmitting light from the secondary light source toward the work surface and reflecting light toward the photogrammetry device. The method further includes scanning the targets with a laser beam generated by the laser source for reflecting the laser beam toward a laser sensor and calculating a location for projecting the laser image onto the work surface from the reflected laser beam.

Abstract: A laser projector assembly for projecting a template onto an object is provided. The laser projector assembly includes a frame, a laser source for generating a laser beam being affixed to said frame, a sensor assembly, a lens assembly and a galvanometer assembly. The sensor assembly is affixed to said frame for identifying surface locations of three dimensional objects. The lens assembly includes a tunable lens for changing a focus of the laser beam received from said laser source. The galvanometer assembly redirects the laser beam received from said lens assembly along a scanning path. The lens is disposed in a fixed location relative to said sensor assembly and is tunable in response to the surface locations of the three dimensional objects identified along the scanning path of the laser beam by said sensor assembly.

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 rotary stage assembly includes a platform and a rotary drive defining an axis of rotation. The platform is mounted on a spindle for receiving rotary movement from the rotary drive. A cylindrical wall is attached to the platform receiving rotary movement from the rotary drive and is coaxial with the axis of rotation defined by the rotary drive. The cylindrical wall defines an inner surface including reference patterns. An imaging assembly images the reference patterns on the inner surface of the cylindrical wall. The imaging assembly detects angular orientation and tilt of the platform from an axis of rotation of the platform from imaging the reference patterns on the inner surface of the cylindrical wall. A controller calculates angular orientation and tilt of the platform from the location of said reference patterns signaled from the imaging assembly.

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 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 identifying accurate location of a component onto a workpiece is disclosed. A laser projector projects laser images relative to the workpiece. An imaging device generates a video image and a display device displays the video image from a view of the imaging device. The display device generates a video image from a view of the workpiece by the imaging device. The laser projector projects a plurality of laser images relative to the workpiece and the display device registers the view of the imaging device relative to the workpiece from the plurality of laser images. The display device generates a virtual image of the component upon the video image of workpiece. The virtual image of the component disposed in a geometrically accurate location upon the video image of 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 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.