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 projection system having personnel protection utilizes a proximity detector system to detect any approach by an operator or other personnel within a predetermined protection zone. If an approach by personnel is detected within a predetermined zone, the laser output is either interrupted or reduced to a safe level, e.g., such as less than 5 mW, or to a level defined as safe for the detected approach distance. Alternatively, the proximity detector system can also utilize an array of highly directional proximity detectors, infrared detectors, and/or incorporation of a detection mechanism onto the laser projection system frame itself. An electronic circuit directly modifies the output power of the laser projector to an approved level based on feedback of the speed of the scanned beam and the detected closest approach distance.

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 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 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 method for determining the position of a laser projector relative to a large tool includes the use of posts having several reference points. The rotating tool is preferably also provided with a plurality of reference points. At least two of the reference points are spaced by a known distance. By identifying the location of the reference points, a control for the system is able to calibrate where the reference points are relative to the laser projectors. In this way, the laser projector is able to calibrate itself relative to the reference points on the large tool. The invention improves upon the prior art in that the location of the reference points need not be fixed relative to the workpiece. Instead, the system will initially determine the position of the reference points based upon known distances between the reference points.

Abstract: An improved method of calibrating a laser projector to reference points includes the steps of moving a reflective member in the path of a laser beam. The reflective member is moved towards a reference point, and a control for the laser projector operates in one mode of operation to move the laser beam with the reflective member. The reflective member is moved, and moves the laser beam towards one of the reference points. Once the laser beam is adjacent to the reference point, the reflective member is removed from the laser beam member. The laser projector then identifies the location of the reference point, and begins to calibrate itself relative to the work surface. This process is repeated until the calibration is complete.

Abstract: An improved method of calibrating the location of a laser projector relative to a workpiece utilizes a series of randomly-placed reference points, with at least two of the points being spaced by a known distance. Known calibration equations allow the identification of the location of the laser relative to the workpiece by identifying the location of the laser relative to the points, and also utilizing the known distance. The laser may be utilized with at least one other component. The second component might be a second laser. If there are reference points fixed relative to a frame of reference then the laser may also be utilized to accurately display information on the workpiece.

Abstract: A system combines a galvanometer system with a camera to provide information from a workpiece to the camera. The galvanometer rotates mirrors to change the image that is directed from the workpiece into the camera. The inventive method allows the use of the camera to identify the location of points on the workpiece. Further, the system facilitates the use of the camera to store information about a pattern on a workpiece. Also, the system can be utilized to create a computer aided design file of the surface of a workpiece. The system is utilized in the last two methods to serially store bit by bit information about the workpiece in a memory.

Abstract: A laser projection system for projecting an image onto a surface comprises a laser projector operably connectable to a computer. The computer controls the operation of the system. The laser projector comprises a laser beam source for generating a laser light beam, a collimator comprising a focusing leans for focusing the laser light beam to a focal point, a collimating lens for collimating the laser light beam beyond the focal point and a wedge-shaped lens having an apertured interposed between the focusing lens and collimating lens. The aperture has a size for passing the laser light beam therethrough. Two scanners direct the light beam about a light path. A photo sensor receives light refracted by the wedge-shaped lens and generates a feedback signal. A plurality of target reflectors, each having a retroreflective material for retroreflecting light back to its source.