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 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 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 method and apparatus for verifying location and orientation of a piece attached to a work surface for s manufacturing a workpiece is disclosed. A controller is programmed with design data for manufacturing steps. Multiple layers of ply are sequentially layered over a work surface. An imaging system capable of redirecting a field of view along the work surface is provided. A light projector is provided for projecting reference features onto the work surface. The light projector projects a reference feature to a known location relative to the piece applied to the work surface within the field of view of the imaging device. The imaging device generates an image of the reference features projected by the light projector and of the piece applied onto the work surface. The controller compares the location of the piece on the work surface with the design data validating accurate placement of the piece.

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 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 of optically scanning indicia on an object includes providing a coherent light source for illuminating the object with coherent light. The object is marked with indicia including a first feature and a second feature, with the first feature including reflection of coherent light and said second feature including emittance of non-coherent light when illuminated. An imaging device is capable of distinguishing coherent light from non-coherent light. The indicia are illuminated with coherent light generated by the coherent light source causing the indicia to reflect coherent light and emit non-coherent light. The coherent light is distinguished from the non-coherent light emitted from the indicia by a controller for identifying a pattern of one of said first feature and said second feature.

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 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 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 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 method and apparatus for verifying location and orientation of a piece attached to a work surface for s manufacturing a workpiece is disclosed. A controller is programmed with design data for manufacturing steps. Multiple layers of ply are sequentially layered over a work surface. An imaging system capable of redirecting a field of view along the work surface is provided. A light projector is provided for projecting reference features onto the work surface. The light projector projects a reference feature to a known location relative to the piece applied to the work surface within the field of view of the imaging device. The imaging device generates an image of the reference features projected by the light projector and of the piece applied onto the work surface. The controller compares the location of the piece on the work surface with the design data validating accurate placement of the piece.

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 optically scanning indicia on an object includes providing a coherent light source for illuminating the object with coherent light. The object is marked with indicia including a first feature and a second feature, with the first feature including reflection of coherent light and said second feature including emittance of non-coherent light when illuminated. An imaging device is capable of distinguishing coherent light from non-coherent light. The indicia are illuminated with coherent light generated by the coherent light source causing the indicia to reflect coherent light and emit non-coherent light. The coherent light is distinguished from the non-coherent light emitted from the indicia by a controller for identifying a pattern of one of said first feature and said second feature.