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 imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift.

Abstract: A laser metrology system for determining a location of a target utilizes a laser projector having a laser source for projecting a laser beam. A rotating head directs the laser beam in a lateral direction. A sensor associated with the laser projector is capable of sensing the laser beam. A reflective target is configured to reflect the laser beam projector from the laser source toward the sensor in a manner indicative of the angle of the rotating head and the pulse of the laser beam to determine location of the target.

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: A laser imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift.

Abstract: A laser imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift.

Abstract: A laser imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift.

Abstract: A laser imaging system and method of projecting a laser template on a surface, including independently determining a position and orientation of the surface using an external metrology device, independently determining a position and orientation of a laser projector using the metrology device, generating a signal from the metrology device to a computer and orienting the laser projector relative to the surface to project a laser template. The apparatus includes a plurality of metrology transmitters at fixed locations, a plurality of metrology receivers at fixed locations relative to the surface and a plurality of metrology receivers at fixed locations relative to either the laser projector or laser targets within a field of view of the laser projector. A laser projector and frame assembly is also disclosed, wherein the metrology receivers are located on the frame and the frame includes laser targets for correcting laser drift.

Abstract: A laser metrology system for determining a location of a target utilizes a laser projector having a laser source for projecting a laser beam. A rotating head directs the laser beam in a lateral direction. A sensor associated with the laser projector is capable of sensing the laser beam. A reflective target is configured to reflect the laser beam projector from the laser source toward the sensor in a manner indicative of the angle of the rotating head and the pulse of the laser beam to determine location of the target.

Abstract: A laser projection system, intelligent data correction system and method which corrects for differences between the as-built condition and the as-designed condition of a workpiece which includes determining the as-built condition of a workpiece with a digitizer scanner and modifying data of the as-built condition or the data of a laser projection based upon the data received from the digitizer scanner of the as-built condition. A preferred intelligent data correction system includes metrology receivers fixed relative to the digitizer scanner and the workpiece and a metrology transmitter to determine the precise location and orientation of the digitizer scanner relative to the workpiece.

Abstract: A multiple laser head projector includes a sensor that senses the presence or absence of a laser beam from a first of the laser heads and signals a switching device to switch to a second laser head when a laser beam is not detected by the sensor from the first laser head. Thus, the multiple laser head projector may be utilized to provide continuous operation of the multiple head laser projector when one of the lasers fails. The multiple head laser projector may also be utilized for diagnostic testing of the laser heads, such as during start-up. Further, the multiple head laser projector may be utilized to signal the power output of the laser heads and thus the expected remaining life of the laser heads.

Abstract: A laser projector includes a laser, scanning mirrors projecting a laser line image on a surface, a computer including an algorithm controlling a speed of the laser line image, and a computer screen having a user interface. The user interface includes a throttle control which modifies the speed control algorithm permitting an operator to reduce the maximum speed of the projected laser line image using the throttle control, thereby improving the visibility of the laser line image. For example, a method of improving the visibility of a projected laser line image includes projecting a laser line image on a surface to determine the visibility of the laser line image and decreasing the maximum scanning speed of the projected laser line image if the visibility of the laser line image is insufficient.

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.