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 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 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 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 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 projector including a cooling system having an internal wall dividing the housing into a first compartment containing the optical components and a second compartment containing the electrical components, wherein the internal wall has a first face receiving the optical components and a second face receiving the electrical components thermally isolated from the first face. The internal wall includes a cooling channel and a fan directs air through the channel to maintain the optical components below a maximum operating temperature. The internal wall in one disclosed embodiment includes two parallel wall members each having a plurality of parallel channels, a thermoelectric cooling element located on the wall adjacent the first compartment, a sensor is located in the first compartment and a control maintains a temperature below ambient in the first chamber.

Abstract: A high precision positioning device includes an end effector and a platen spaced therebelow for receiving a workpiece. One of the end effector and the platen is moveable in the X-Y plane. One of the end effector and the platen is moveable in the Z direction. The device includes senors for sensing the position of the end effector in the X, Y and Z directions relative to the platen. The apparatus includes a control system for controlling the movement of the end effector relative to the platen and adjusting the position of the end effector relative to the X. Y and Z position as sensed by the sensors. Preferably the platen is generally parallel to the X-Y plane and the Z direction is normal to the platen. Preferably the control system uses a position, velocity and acceleration control system for controlling the movement in the X and Y direction and an impedance control system for controlling the movement in the Z direction.