US20030106226A1 - Alignment device - Google Patents
Alignment device Download PDFInfo
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- US20030106226A1 US20030106226A1 US10/279,754 US27975402A US2003106226A1 US 20030106226 A1 US20030106226 A1 US 20030106226A1 US 27975402 A US27975402 A US 27975402A US 2003106226 A1 US2003106226 A1 US 2003106226A1
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- Prior art keywords
- alignment
- mounting assembly
- alignment device
- optics mounting
- level
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01C—MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
- G01C15/00—Surveying instruments or accessories not provided for in groups G01C1/00 - G01C13/00
- G01C15/002—Active optical surveying means
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S33/00—Geometrical instruments
- Y10S33/21—Geometrical instruments with laser
Definitions
- the present invention is directed to the field of alignment devices.
- a project requires the use of multiple references.
- a project may require the use of both reference lines and planes in horizontal and vertical orientation.
- this requires the use of multiple alignment tools—forcing a person to have all of these tools available for the project.
- the purchase, maintenance, storage, and transportation of several alignment tools are undesirable inconveniences that consume time and money. In some circumstances it is simply impractical to have multiple alignment tools readily available on a job site.
- backlash can be a leading source of inaccuracy.
- the movement of a first object directs the motion of a second object.
- Backlash is the phenomenon of mechanical hysteresis that occurs when the direction of motion of the first object is altered.
- Mechanisms controlling the motion of the second object by directing the motion of the first object need to account for backlash. Otherwise, the control system's accuracy will be compromised.
- a multiple reference alignment tool needs to either reduce or compensate for backlash in all of the orientations the tool will be used.
- the present invention pertains to an alignment device capable of providing multiple references in different orientations—reducing the number of alignment devices a user needs for a job site.
- One implementation of the alignment device provides a horizontal set of laser references and a vertical set of laser references. For each set of references, users have the ability to select a plane, line, or pointing reference.
- users can also rotate the position of the vertical and horizontal reference points and lines.
- users can adjust the positions of the laser planes on incident surfaces.
- One embodiment of the alignment device includes an optics mounting assembly mounted in a pivot socket on a frame.
- a spring system and one or more alignment assemblies secure the optics mounting assembly in the pivot socket.
- the optics mounting assembly includes a light source supplying a light beam.
- the light source is a laser emitting diode supplying a laser beam.
- the source beam is incident on a reflector that produces an output reference beam. At rest, the reflector produces a reference point.
- a motor mounted on the optics mounting assembly spins the reflector to generate a reference plane. The motor dithers the reflector to generate a reference line.
- a user can manually position the output reference beam.
- the pivot socket has a surface in the form of a sphere's interior surface.
- the optics mounting assembly extends through the pivot socket and includes a set of support members that rest on the pivot socket's spherical surface.
- the support members hold the reflector in a position that results in the output reference beam originating at the center of a sphere that includes the pivot socket's spherical surface. This minimizes translation of the output reference beam's origin when the optics mounting assembly pivots in the socket.
- the spring system includes a set of one or more springs exerting force on the optics mounting assembly.
- the spring force pulls the optics mounting assembly support arms against the spherical surface of the pivot socket.
- the spring force also attempts to rotate the optics mounting assembly about a pivot point at the center of a sphere that includes the spherical surface of the socket.
- the optics mounting assembly includes a set of extension arms that communicate with the alignment assemblies. The alignment assemblies apply forces on the extension arms that oppose the rotation induced by the spring force—holding the optics mounting assembly in a desired position within the pivot socket.
- Alignment assembly movements direct the movement of the optics mounting assembly—altering the position of the output reference beam.
- the alignment device includes a level sensor that supplies signals indicating whether the optics mounting assembly is normal to true level.
- a control subsystem in the alignment device employs these signals to drive the alignment assemblies.
- the alignment assemblies provide forces to the optical mounting assembly extension arms—positioning the optics mounting assembly normal to true level. This results in an output reference beam parallel to true level.
- the spring system assists in removing backlash from the alignment device's controlled movement of the optics mounting assembly.
- the spring system holds the extension arms flush against pads on the alignment assemblies.
- the optics mounting assembly support arms are held flush against the spherical surface of the pivot socket by the combined forces of the (1) alignment assemblies on the extension arms and (2) the spring system on the optics mounting assembly.
- each alignment assembly pad is mounted on a lead screw with a gear driven by a motor controlled pinion.
- the pinion's teeth are tightly coupled to the gear's teeth to further reduce backlash.
- the pinion and gear are drawn together by a spring force that allows the gear and pinion teeth to separate, as needed, to minimize backlash and compensate for run-out.
- the alignment device also produces an accurate reference beam when the device is rotated by ninety degrees—converting a horizontal laser plane generated by the reference beam into a vertical laser plane.
- the spring system and alignment assemblies provide the same forces in the rotated orientation to secure the position of the optics mounting assembly and remove backlash effects.
- the alignment assemblies can be employed to control the positioning of the output reference beam on an incident surface.
- the alignment assemblies may horizontally translate a vertical laser plane output on the incident surface.
- the reflector can be a penta-prism mounted with a predefined pitch for reducing the effects of satellite output beams.
- the penta-prism may also include a predetermined pitch deviation. The penta-prism is then mounted within a known roll range to achieve a more accurately positioned reference beam.
- Alignment devices in alternate embodiments of the present invention may provide less than all of the references described above.
- One version of an alignment device according to the present invention only provides a single type of reference in a single orientation.
- aspects of the present invention can be accomplished using hardware, software, or a combination of both hardware and software.
- the software used for the present invention is stored on one or more processor readable storage media including hard disk drives, CD-ROMs, DVDs, optical disks, floppy disks, tape drives, RAM, ROM or other suitable storage devices.
- processor readable storage media including hard disk drives, CD-ROMs, DVDs, optical disks, floppy disks, tape drives, RAM, ROM or other suitable storage devices.
- some or all of the software can be replaced by dedicated hardware including custom integrated circuits, gate arrays, FPGAs, PLDs, and special purpose computers.
- FIG. 1 depicts the exterior of an alignment device in one embodiment of the present invention.
- FIGS. 2 A- 2 B show perspective views of internal components in one version of the alignment device in FIG. 1.
- FIG. 2C shows a front view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2D shows a rear view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2E shows a perspective bottom view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2F shows a bottom view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2G shows a top view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2H shows a side view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2I shows a cross-sectional side view of internal components in one version of the alignment device in FIG. 1.
- FIG. 3 is a side-section view of one implementation of a dual axis level sensor.
- FIG. 4 is a perspective view of an implementation of a dual axis level sensor.
- FIG. 5 depicts an embodiment of a quadrature detector in accordance with the present invention.
- FIGS. 6 and 7 are side-section views of additional level sensor embodiments in accordance with the principles of the present invention.
- FIG. 8 shows a cross-sectional view of a jack screw assembly mounting a laser sensor to an optics mounting assembly in one embodiment of the present invention.
- FIG. 9 shows a penta-prism used in one embodiment of the present invention as a reflector.
- FIGS. 10 A- 10 C shows alternate embodiments of a penta-prism and implementations for mounting a penta-prism.
- FIGS. 11 A- 11 B show various perspective views of one embodiment of a rotation cap for use in the alignment device shown in FIG. 1.
- FIG. 12 shows a perspective view of the spring mechanism in the rotation cap shown in FIGS. 11 A- 11 B.
- FIG. 13 is a block diagram for one implementation of a control subsystem for the alignment device in FIG. 1.
- FIG. 14 is a flowchart describing one implementation of a process for leveling a horizontal reference.
- FIG. 15 is a flowchart describing one implementation of a process for setting a horizontal reference to a predetermined offset.
- FIG. 16 is a flowchart describing one implementation of a process for leveling a vertical reference.
- FIG. 17 is a flowchart describing one implementation of a process for setting a vertical reference to a predetermined offset.
- FIG. 18 is a flowchart describing one version of a process for positioning horizontal and vertical references.
- FIG. 1 shows a laser alignment device 1 in accordance with the present invention.
- Output beam 8 emanates from beam turret 4 , which is mounted on top of alignment device 1 .
- output beam 8 is a laser beam, while in alternate embodiments output beam 8 can be any type of light, including visible and invisible light.
- Alignment device 1 uses output beam 8 to provide reference points, lines, and planes on incident surfaces. In the orientation shown in FIG. 1, alignment device 1 provides horizontal reference lines and planes. When alignment device 1 is rotated by ninety degrees, output beam 8 provides vertical reference lines and planes. The rotated operation of alignment device 1 is described below in greater detail.
- the position of output beam 8 can be rotated to adjust the position of a reference line or point.
- a user manually rotates rotation cap 6 on turret 4 to make an angular adjustment to the position of a output beam 8 .
- alignment device 1 automates the angular adjustment of output beam 8 .
- Local interface 10 on alignment device 1 includes control buttons that enable users to control the operation of alignment device 1 . This allows users to generate and position horizontal and vertical references.
- alignment device 1 includes a remote control receiver (not shown).
- the remote control receiver enables communication with a remote control, so a user can remotely direct the operation of alignment device 1 .
- a remote control receiver can support any one of a number of different communication mediums and protocols. For example, in one embodiment, the remote control receiver supports radio frequency communication, while in another embodiment the receiver supports infrared signaling.
- FIGS. 2 A- 2 I show one implementation of internal components for alignment device 1 in accordance with the present invention.
- FIGS. 2 A- 2 I show different views as described above.
- laser source 116 is mounted in mounting device 117 , which is press fit into the hollow main shaft of optics mounting assembly 24 .
- laser source 116 is a laser emitting diode coupled to circuit board 120
- mounting device 117 is a mounting joint, as described in U.S. patent application Ser. No. 09/928,244.
- Collimating lens 134 is mounted in mount fixture 102 , which is fitted into the main shaft of optics mounting assembly 24 in line with laser source 116 .
- Optics mounting assembly 24 houses hollow rotation shaft 98 , which extends through guide rings 130 and 132 .
- rotating support ring 106 supports rotation shaft 98 in line with collimating lens 134 .
- Shaft 98 supports reflector 96 in line with lens 134 and laser source 116 .
- a laser beam from source 116 extends through lens 134 and onto reflector 96 , which converts the beam from source 116 into output beam 8 .
- Motor 108 on optics mounting assembly 24 drives the rotation of support ring 106 to rotate shaft 98 .
- Shaft 112 from motor 108 is coupled to belt drive gear 114 .
- Belt 104 extends around support ring 106 and gear 114 .
- motor 108 rotates shaft 112 , which rotates gear 114 .
- the rotation of gear 114 drives belt 104 to rotate support ring 106 —resulting in the rotation of output beam 8 .
- a control subsystem in alignment device 1 employs motor 108 to perform the following operations: 1) spinning reflector 96 to generate a laser plane reference; 2) dithering reflector 96 to generate a partial laser plane reference; and 3) adjusting the rotation of reflector 96 to position a laser reference point.
- Encoder 110 is mounted on shaft 112 to facilitate dithering and pointing.
- Alignment device 1 sets and secures the position of optics mounting assembly 24 , so that output beam 8 has a desired orientation with respect to true level.
- alignment device 1 provides for optics mounting assembly 24 to produce output beam 8 as parallel to true level.
- alignment device 1 stabilizes optics mounting assembly 24 to have a predetermined offset from true level.
- optics mounting assembly 24 extends through pivot socket 22 on frame 20 .
- Optics mounting assembly 24 includes support members 28 , 30 , and 32 resting on section 23 of pivot socket 22 .
- Section 23 is formed in the shape of a section from an interior surface of a sphere.
- Spherical section 23 extends downward from rim 26 on socket 22 , which is used to mount socket 22 to frame 20 .
- pivot socket 22 is formed in housing 20 .
- Alignment device 1 adjusts the position of optics mounting assembly 24 within pivot socket 22 to give output beam 8 a desired orientation, such as parallel to true level.
- members 28 , 30 , and 32 support optics mounting assembly 24 , so that output beam 8 originates from reflector 96 at a point in the center of a sphere including spherical section 23 .
- This center point also serves as the pivot point for assembly 24 . This eliminates translation of the output beam origin when alignment device 1 adjusts the position of optics mounting assembly 24 within pivot socket 24 .
- the origin of output beam 8 may deviate from the sphere center point.
- section 23 can have a non-spherical surface.
- Optics mounting assembly 24 includes extension arms 34 and 36 . As will be described below, forces applied to extension arms 34 and 36 assist in adjusting the orientation of optics mounting assembly 24 . In one implementation, extension arms 34 and 36 extend from the center of optics mounting assembly 24 perpendicular to each other.
- Alignment assemblies within alignment device 1 provide adjustment forces to extension arms 34 and 36 .
- An alignment assembly in communication with extension arm 36 includes motor 54 , which rotates shaft 52 .
- Pinion 50 is mounted on shaft 52 and has teeth in communication with teeth on gear 48 .
- Lead screw 46 is mounted to gear 48 , so that screw 46 rotates when gear 48 rotates.
- Lead screw 46 extends through lead nut 44 , so that lead nut 44 translates along lead screw 46 , based on the direction that screw 46 rotates.
- Alignment force pad 42 is coupled to nut 44 , so that pad 42 follows the translation path of nut 44 .
- pad 42 includes interface contact 141 to communicate with extension arm 36 . (See FIG. 2C.)
- contact 141 has a spherical surface that enhances the ability of pad 42 to move extension arm 36 without binding.
- the teeth of pinion 50 are tightly interlocked with the teeth of gear 48 to reduce backlash in the operation of the alignment assembly.
- gear 48 and pinion 50 are held in communication by spring 150 —reducing backlash and compensating for run-out.
- Spring 50 reduces backlash by pulling the teeth of gear 48 and pinion 50 tightly together in operation.
- Spring 50 also reduces run-out.
- motor mount 152 supports motor 54 .
- Motor mount 152 is mounted to frame 20 so that mount 152 can pivot pinion 50 away from and toward gear 48 .
- Spring 150 is coupled to motor mount 152 and frame 20 to facilitate the above-described operation between the teeth of gear 48 and pinion 50 .
- An alignment assembly in communication with extension arm 34 includes motor 74 , which rotates shaft 72 .
- Pinion 70 is mounted on shaft 72 and has teeth in communication with teeth on gear 68 .
- Lead screw 66 is mounted to gear 68 , so that screw 66 rotates when gear 68 rotates.
- Lead screw 66 extends through lead nut 64 , so that lead nut 64 translates along lead screw 66 , based on the direction that screw 66 rotates.
- Alignment force pad 62 is coupled to nut 64 , so that pad 62 follows the translation path of nut 64 .
- pad 62 includes interface contact 140 to communicate with extension arm 34 .
- contact 140 has a spherical surface that enhances the ability of pad 62 to move extension arm 34 without binding.
- the teeth of pinion 70 are tightly interlocked with the teeth of gear 68 to reduce backlash in the operation of the alignment assembly.
- Gear 68 and pinion 70 are held in communication by spring 160 (not shown, but operating like spring 150 ) to reduce backlash and compensate for run-out.
- Spring 160 reduces backlash by pulling the teeth of gear 68 and pinion 70 tightly together in operation. Spring 160 also reduces run-out effects.
- motor mount 162 supports motor 74 .
- Motor mount 162 is mounted to frame 20 so that mount 162 can pivot pinion 70 away from and toward gear 68 .
- Spring 160 is coupled to motor mount 162 and frame 20 to facilitate the above-described operation between the teeth of gear 68 and pinion 70 .
- a spring set in alignment device 1 pulls optics mounting assembly 24 into pivot socket 22 and directs extension arms 34 and 36 against pads 62 and 42 , respectively.
- the spring set includes two springs. In alternate embodiments, more or less than two springs are employed.
- the spring set has springs 38 and 40 .
- Springs 38 and 40 each have a first end mounted to frame 20 and a second end mounted to optics mounting assembly 24 .
- Springs 38 and 40 each supply a force with a component pulling support member 28 , 30 , and 32 against spherical section 23 of pivot socket 22 .
- the forces from springs 38 and 40 also have components that direct optics mounting assembly 24 to rotate about a pivot point at the center of a sphere including spherical section 23 —pulling extension arms 34 and 36 against pads 62 and 42 , respectively.
- the forces from pads 62 and 42 on extension arms 34 and 36 respectively, oppose the spring forces to hold optics mounting assembly 24 in place.
- the combined forces from springs 38 and 40 and alignment assembly pads 62 and 42 further reduce backlash in alignment device 1 . These forces ensure that support member 28 , 30 , and 32 are flush against spherical section 23 and extension arms 34 and 36 are flush against pads 62 and 42 , respectively.
- a control subsystem in alignment device 1 adjusts the position of output beam 8 by using the alignment assemblies to adjust the position of optics mounting assembly 24 .
- the lag time between driving motors 54 and 74 and effecting motion on extension arms 40 and 38 is minimized, because pads 62 and 42 are in constant contact with arms 34 and 36 , respectively.
- springs 38 and 40 are constant force springs that exert constant forces regardless of how far they are stretched. In an alternate embodiment, the spring force of springs 38 and 40 vary with the distance the springs are stretched. In one such embodiment, springs 38 and 40 are positioned to minimize the amount of stretching the springs will experience. In one example, springs 38 and 40 are mounted to have the least amount of stretching possible and still apply sufficient force to bias extension arms 36 and 34 onto pads 62 and 42 and retain assembly 24 in socket 22 . In one implementation, these constraints are met for the entire allowed range of motion for assembly 24 , including the rotated position of alignment device 1 to produce a vertical reference plane as described herein. In an additional implementation, springs 38 and 40 do not contact assembly 24 , except in the points where springs 38 and 40 are anchored to assembly 24 .
- extension arms 34 and 36 are replaced by a pair of fine leads that rest on the grooves in lead screws 46 and 66 .
- the fine leads are perpendicular to each other. Rotating screws 46 and 66 causes the fine leads to slide up or down screws 46 and 66 , based on the direction of rotation causing the position of optics mounting assembly 24 in pivot socket 22 to be adjusted.
- the fine lead embodiment also reduces backlash effects, since the leads rest directly on the grooves in screws 46 and 66 .
- the fine leads are cylindrical and rigid with the dimensions of standard piano wire. In one example, the fine lead diameter is 1 millimeter or less.
- Screws 44 and 46 can be machined with very fine threads to allow for alignment adjustments with fine granularity.
- the fine screw threads do not create a need for expensive fine thread nuts, since lead nuts 44 and 64 and pads 42 and 62 are no longer needed.
- a surface on either arm 34 or arm 36 that contacts pad 62 or pad 42 has a groove (not shown).
- the groove receives the respective spherical contact 140 or 141 .
- the groove eliminates rotation of the contact ( 140 or 141 ) on the arm ( 34 or 36 ). This ensures that arms 34 and 36 move along the desired path in response to alignment assembly forces.
- optics mounting assembly 24 is replaced by a pendulum assembly that supports the above-described optical elements, including a motor for rotating reflector 96 .
- the pendulum base includes shafts that support one or more balancing weights.
- the alignment assemblies are modified to slide the weights along the pendulum base shafts to adjust the pendulum's center of gravity. These adjustments modify the position of output beam 8 .
- One version of alignment device 1 also has the capability to self-level—automatically bringing output beam 8 into a parallel relationship with true level.
- level sensor 80 is mounted to optics mounting assembly 24 to determine whether the central axis of assembly 24 is normal to true level.
- Level sensor 80 provides level indicators to a control subsystem in alignment device 1 .
- the control subsystem drives motors 54 and 74 to bring optics mounting assembly 24 into a perpendicular relationship with true level.
- Example embodiments of level sensor 80 are disclosed in U.S. patent application Ser. No. 10/004,694.
- FIGS. 3 - 7 show various implementation of level sensor 80 .
- FIG. 3 shows detector element 230 in level sensor 80 , including position sensitive photo sensor 231 , two-axis bubble level 232 , aperture structure 229 , and detector light source 233 for generating detector light beam 234 (also referred to as detector light).
- Detector light 234 is passed through bubble level 232 onto position sensitive photo sensor 231 , which detects whether bubble level 232 is leveled. Since the illustrated embodiment is tiltable in two degrees of freedom, a detector (e.g. bubble level) that is sensitive to tilting in two degrees of freedom is particularly appropriate. In other embodiments, an angled pair of one-dimensional tilt detectors may be used. It is to be noted that other embodiments of detector elements can be used in accordance with the principles of the present invention.
- bubble level 232 can include a curved bubble face 236 .
- curved bubble face 236 has a radius of curvature of 70 millimeters.
- Position sensitive photo sensor 231 can incorporate any of a number of commercially available position sensitive detectors sensitive to detector light 234 .
- Examples include, but are not limited to, quadrature detectors, charged coupled device (CCD) detectors, complementary metal oxide semiconductor (CMOS) image sensors (such as that taught in U.S. Pat. No. 5,461,425 to Fowler, et al. hereby incorporated by reference).
- CMOS complementary metal oxide semiconductor
- FIG. 4 is a perspective view of an embodiment of a two-axis detector element 230 in accordance with the principles of the present invention.
- Light source 233 generates a beam that passes through aperture 229 (See FIG. 3) to produce detector light beam 234 that is directed through two-axis bubble level 232 onto quadrature detector 231 .
- Detector light 234 passes readily through fluid 237 but is refracted in large part by bubble 235 of two-axis bubble level 232 . Consequently, detector light 234 forms ring of light 238 surrounding dark spot 239 . Ring 238 and spot 239 track the movement of bubble 235 as detector element 230 (and by consequence the output beams) is tilted.
- Bubble detector embodiments can be constructed such that the inside walls of the bubble container are not easily wetted by the fluids contained therein.
- the fluid can be water and the inside surface of the bubble container can be treated with hydrophobic material.
- FIG. 5 depicts an embodiment of quadrature detector 231 featuring dark spot 239 and light ring 238 .
- quadrature detector 231 is fully illuminated within ring 238 except for dark spot 239 .
- dark spot 239 moves with respect to quadrature detector 231 .
- quadrature detector 231 provides leveling information.
- the detector element is calibrated so that the output beams are leveled when dark spot 239 is centered in quadrature detector 231 .
- Quadrature detector 231 has four photodetectors 241 , 242 , 243 , and 244 .
- electrical current is produced.
- the magnitude of the current bears a relationship to the intensity of the light impinging on photodetectors 241 , 242 , 243 , and 244 .
- This light intensity is reduced by the presence of dark spot 239 .
- the control subsystem in device 1 measures the current produced by the photodetectors and processes the current to determine the location of dark spot 239 on quadrature detector 231 .
- the current produced by the photodetectors is conducted away from the detector using conductive lines 240 , which can be connected to the control subsystem of device 1 .
- the current from photodetectors 241 , 242 , 243 , and 244 is processed to determine the position of dark spot 139 .
- One example of a method used to determine spot 239 position is as follows: In order to determine the left/right (L/R) position of the spot 239 , current I 241 produced from photodetector 241 is summed with current I 243 produced by photodetector 243 , and current I 242 produced by photodetector 242 is summed with current I 244 produced photodetector 244 . The two sums are normalized and subtracted from each other as shown in the equation below.
- the up and down positions of the spot can also be determined with quadrature detector 231 .
- quadrature detector 231 For example, in accordance with the following equation:
- spot 239 is too low. Conversely, if the up/down position current is negative, then spot 239 is too high. If the depicted spot 239 is used as an example, the left/right position current will be negative and the up/down position current will be positive, which will allow the control subsystem to detect the fact that the beam is in the quadrant detected by photodetector 243 . Based on this information, the alignment assemblies are activated to adjust the position of optics mounting assembly 24 in order to move dark spot 239 higher and to the right to level the bubble, thereby leveling output beam 8 .
- light ring 238 (and dark spot 239 ) can be generated by a plurality of laser emitting diodes (LED's). Once the device is leveled, the brightness of each of these LED's can be adjusted until dark spot 239 is centered on light detector 231 . This is advantageous because it can be accomplished electronically without the need for costly and time consuming alignment steps. Instead, simple adjustment of LED brightness can be used to center the dark spot 139 in a calibration step. One such embodiment can use four LED's.
- LED's laser emitting diodes
- FIG. 6 depicts the operation of yet another sensor embodiment 250 .
- the sensor element is depicted in a cross-section view.
- Sensor element 250 includes position sensitive photo sensor 281 , bubble level device 252 , aperture structure 279 , and detector light source 283 for generating detector light beam 284 (also referred to as detector light).
- detector light beam 284 also referred to as detector light
- many different types of detector light sources 283 can be used, such as LED's.
- Detector light 284 is passed through bubble level device 252 onto position sensitive photo sensor 281 , which detects whether bubble level device 252 is leveled (as is the case in FIG. 6).
- bubble fluid 253 is treated so that it is relatively opaque to detector light 284 .
- a dye can be added to bubble fluid 253 , so that a portion of the detector light passes through bubble level device 252 in the region of bubble 255 , but not through fluid 253 .
- detector beam 284 passes readily through bubble 255 of bubble level 252 , but is absorbed by fluid 253 .
- detector light beam 256 exits bubble level 252 .
- this detector light beam 256 is characterized by a light spot defined by bubble 255 .
- sensor 250 can be oriented so that beam 284 points downward.
- FIG. 7 shows detector 250 tilted to the left. Consequently, bubble 255 moves to the right, altering the amount and position of light 256 sensed by position sensitive photo sensor 281 .
- position sensitive photo sensor 281 provides information to control circuitry (not shown here) which activates the alignment assemblies to correct the tilt in output beam 8 .
- the position sensitive photo detectors work similarly to those described hereinabove. The chief difference being that the electrical information is processed by the photo detectors in a slightly different manner to track the light spot as it moves across the photo detectors. Such methods are known to those having ordinary skill in the art. In a further embodiment, invisible light can be employed in level sensor 80 .
- Another suitable detector element embodiment can use a pair of single-axis bubble levels arranged at right angles to each other so that a level with respect to a first and second axis can be detected.
- Each single-axis bubble level is associated with a corresponding light source and a corresponding position sensitive detector.
- Each corresponding light source and corresponding position sensitive detector is arranged to detect whether each single-axis bubble level is leveled.
- screw assemblies 82 , 84 , and 86 mount level sensor 80 to optics mounting assembly 24 .
- FIG. 8 shows a cross-sectional view of one embodiment of screw assembly 84 , which can also be used for screw assemblies 82 and 86 .
- the screw assembly in FIG. 8 focuses stresses in the screw connection to reduce stresses on member 300 extending from optics mounting assembly 24 and member 302 extending from level sensor 80 . Taking stress off of member 300 is particularly beneficial, so that the chance of destabilizing optics mounting assembly 24 is reduced.
- Jack screw 312 has a threaded segment that extends into threaded channel 320 in member 300 .
- Screw 306 extends through Bellville washer 308 , washer 310 , unthreaded channel 322 in jack screw 312 , and threaded channel 324 in member 302 .
- Jack screw 312 rests on member 302 , so that channel 322 in jack screw 312 is in line with channel 324 in member 302 .
- Rotating jack screw 312 either pulls members 300 and 302 together or drives members 300 and 302 apart along the central axis of channel 322 in jack screw 312 .
- Rotating screw 306 either pulls members 300 and 302 together or drives members 300 and 302 apart along the central axis of screw 306 .
- Washer 308 is fitted under the head of screw 306 , so that the surface of washer 308 extends downward from an interior circumference to an exterior circumference. This causes the exterior circumference of washer 308 to apply a force toward the surface of member 300 . This force takes pressure off of member 300 when screw 306 is not fully tightened. Without the force from washer 308 , member 300 would tend to pull against the holding force applied by jack screw 312 —creating strain in member 300 . This feature can be useful in the manufacturing process of alignment device 1 , before screw 306 is fully tightened so that washer 308 is driven to be flat like washer 310 .
- FIG. 9 illustrates five-sided penta-prism 400 , which can be employed to operate as reflector 96 .
- Penta-prism 400 produces an output beam perpendicular to a beam entering through input side 402 .
- beam 410 enters penta-prism 400 through side 402 and is reflected by mirrored surface 404 to produce reflected beam 412 .
- Mirrored surface 406 reflects beam 412 to create output beam 8 .
- reflector 96 is implemented with objects other than a penta-prism.
- FIGS. 10 A- 10 C show alternate embodiments for reflector 96 and the mounting of reflector 96 .
- FIG. 10A shows penta-prism 420 , which can be employed to operate as reflector 96 .
- Penta-prism 420 generates output beam 429 in response to input beam 421 .
- Angle 426 is less than the ideal ninety degrees between beams 410 and 8 in penta-prism 400 .
- angle 426 is 5 arc-seconds less than ninety degrees.
- angle 426 is designed with a tolerance of plus or minus 5 arc-seconds. The desired value of angle 426 can be achieved in one embodiment by increasing angle 425 , decreasing angle 427 , or increasing angle 425 and decreasing angle 427 .
- the known decrease in angle 426 is useful for aligning penta-prism 420 , so that output beam 8 is normal to input beam 421 .
- the alignment can be difficult, due to challenges in mounting reflector 96 on rotation shaft 98 with a zero roll alignment.
- a deviation in roll of reflector 96 causes output beam 8 to have an incline—increasing the angle between output beam 8 and input beam 421 .
- a known deviation in angle 425 or 427 that decreases angle 426 makes it acceptable to mount penta-prism 420 with a roll other than zero.
- the decrease in angle 426 is offset by deviations in the roll to move output beam 8 closer to a perpendicular relationship with the input beam to reflector 96 .
- shaft 98 allows reflector 96 to be mounted within plus or minus 0.1 degree of zero roll alignment.
- FIG. 10B shows a cross-section of shaft 98 in one embodiment for mounting an implementation of reflector 96 , such as penta-prism 420 .
- This embodiment of shaft 98 makes it easier to mount penta-prism 420 with a desired roll.
- the V-shaped groove at the top of shaft 98 eliminates any roll effects that would be introduced by imperfections in the top surface of shaft 98 .
- the edges of penta-prism 420 are aligned on the groove surfaces and secured, so that penta-prism 420 has a roll within a desired tolerance.
- penta-prism 420 is secured to shaft 98 with an epoxy.
- shaft 98 allows reflector 96 to be mounted within plus or minus 0.1 degree of zero roll alignment.
- FIG. 10C shows an embodiment of shaft 98 having decline slope 430 on the top surface.
- decline angle 432 is offset two degrees from perpendicular.
- decline angle 432 has a different value.
- different penta-prisms can be employed, such as penta-prism 400 or penta-prism 420 .
- the features of shaft 98 in FIGS. 10B and 10C are both employed in some embodiments, while only one of the features or none of the features are employed in alternate embodiments.
- reflector 96 is partially transmissive, so that a second beam perpendicular to output beam 8 is generated.
- different angular relationships to output beam 8 can be employed.
- penta-prism face 404 or 424 is partially transmissive—allowing the penta-prism's input beam to extend through the penta-prism.
- a refraction-compensated and half-silvered penta-prism is employed.
- a window or other opening can be formed in cap 6 .
- FIGS. 11A and 11B show a perspective view of rotation cap 6 , which can be used to manually rotate the position of reflector 96 .
- Rotation cap 6 allows a user's manual rotation force to be applied, while any extraneous translation forces are ignored.
- rotation shaft 98 extends through reflector rotation mount 94 .
- Rotation mount 94 is coupled to rotation shaft 98 , so that the rotation of mount 94 causes shaft 98 to rotate.
- Mount 94 includes ridge 124 .
- Cap 100 is coupled to ridge 124 , so that rotation force applied to cap 100 causes rotation mount 94 to rotate shaft 98 .
- Rotation cap 6 includes a spring controlled wheel assembly to limit the translational force applied to cap 100 .
- FIG. 12 shows spring controlled wheel assembly 500 including wheels 500 and 502 .
- Prongs 504 and 506 secure axel 512 passing through wheel 500 .
- Prongs 508 and 510 secure axel 514 passing through wheel 502 .
- axel 512 rests on the bottom surfaces of prongs 504 and 506 , as shown in FIG. 12.
- Axel 514 rests on the bottoms of prongs 508 and 510 , as shown in FIG. 12.
- prongs 504 , 506 , 508 , and 510 are formed using flexible sheet metal or steel.
- axels 512 and 514 slide into grooves 520 and 522 , respectively, while maintaining contact with cap 100 .
- the top portions of prongs 504 and 506 apply a force on axel 512 that causes wheel 500 to maintain contact with cap 100 .
- the top portions of prongs 508 and 510 apply a force on axel 514 that causes wheel 502 to maintain contact with cap 100 .
- the friction between the surface of cap 100 and the surfaces of wheels 500 and 502 prevents wheels 500 and 502 from sliding along cap 100 , except for rotation about their respective axels 512 and 514 .
- cap 100 rotating in response to a rotation force applied to rotation cap 6 while cap 6 is depressed.
- This rotation of cap 6 adjusts the position of output beam 8 by rotating shaft 98 .
- the wheel surfaces are rubber and the surface of cap 100 is plastic.
- the intensity of output beam 8 can be reduced during a manual rotation.
- laser output beam 8 is reduced to 20% of its normal intensity.
- alignment device 1 reduces the intensity of output beam 8 upon detecting that level sensor 80 has a predetermined deviation from level. This operation is performed by the control subsystem detecting an out of level indication and reducing the intensity of the beam from laser source 116 .
- different methods can be employed to reduce the intensity of beam 8 .
- the control subsystem ceases all automated rotation of rotation shaft 98 until a level orientation is re-established. This inhibits the generation of laser planes and dithered reference lines.
- a user rotates alignment device 1 by ninety-degrees.
- the user rotates alignment device 1 , so that arms 34 and 36 on optics mounting assembly 24 are directed towards the ground.
- alignment device 1 provides a bubble vial mounted to frame 90 , as shown in FIGS. 2H and 2I.
- bubble vial 90 is on the exposed top surface of alignment device 1 for use by the user in adjusting the position of output beam 8 .
- self-leveling is not provided in the rotated state. In alternate embodiment, self-leveling is provided in the rotated state.
- spring 38 and 40 and the alignment assemblies continue to operate as described above to secure and adjust the position of optics mounting assembly 24 within pivot socket 22 .
- FIG. 13 is a block diagram of control subsystem 624 in alignment device 1 , as well as, alignment motor interface 634 , alignment motor interface 636 , optics motor interface 638 , level sensor interface 639 , local user interface 10 , tilt sensor 600 , and remote user interface 608 .
- Control subsystem 624 controls user interfaces to alignment device 1 and the operation of motors in alignment device 1 .
- Control subsystem 624 includes bus 632 coupling controller 628 , data storage unit 626 , memory 630 , and input/output block 644 .
- Controller 628 is a central processing unit used for executing program code instructions, such as a microprocessor or mircocontroller. In response to program code instructions, controller 628 retrieves and processes data and provides data and control signals.
- Input/output block 644 , data storage unit 626 and memory 630 are all coupled to bus 632 to exchange data and control signals with controller 628 .
- Memory 630 stores, in part, data and instructions for execution by controller 628 . If a process is wholly or partially implemented in software, memory 630 may store the executable instructions for implementing the process when alignment device 1 is in operation. Memory 630 may include banks of dynamic random access memory, static random access memory, read-only memory and other well known memory components
- Data storage unit 626 provides non-volatile storage for data and instructions for use by controller 628 .
- data storage unit 626 may store instructions executed by controller 628 to perform processes.
- Data storage unit 626 may, support portable storage mediums, fixed storage mediums or both
- Data storage unit 626 implements fixed storage mediums using a magnetic disk drive or an optical disk drive.
- Data storage unit 626 supports portable storage mediums by providing a portable storage medium drive that operates in conjunction with portable non-volatile storage mediums—enabling the input and output of data and code to and from control subsystem 624 .
- portable storage mediums include floppy disks, compact disc read only memory, or an integrated circuit non-volatile memory adapter (i.e. PC-MCIA adapter).
- instructions for enabling control subsystem 624 to execute processes are stored on a portable medium and input to control subsystem 624 via a portable storage medium drive.
- control subsystem 624 may be connected through one or more data transport mechanisms.
- controller 628 and memory 630 may be connected via a local microprocessor bus
- data storage unit 626 and input/output block 644 may be connected via one or more input/output (I/O) busses.
- Input/output ports 646 , 648 , 650 , 651 , 652 , 653 , and 654 in input/output block 644 couple bus 632 to alignment motor interface 634 , alignment motor interface 636 , optics motor interface 638 , level sensor interface 639 , local user interface 10 , tilt sensor 600 , and remote user interface 608 , respectively.
- Alignment motor interface 634 is coupled to alignment motor 74 .
- Alignment motor interface 636 is coupled to alignment motor 54 .
- Optics motor interface 638 is coupled to optics motor 108 .
- Motor interfaces 634 , 636 , and 638 provide conversions between the digital data and control signaling of control subsystem 624 and the analog signaling of the motors.
- optics motor 80 has fine cogging and provides sufficient torque to rotate reflector 96 .
- Alignment motors 54 and 74 also have fine cogging in one embodiment.
- Level sensor interface 639 is coupled to level sensor 80 to receive level indicator signals and pass them to input/output port 651 —converting the analog signals of level sensor 80 into digital signals.
- Tilt sensor 600 is coupled to input/output port 653 to indicate when alignment device 1 has been rotated to provide vertical references.
- Input/output ports 652 and 654 in input/output block 644 couple bus 632 to user interfaces 10 and 608 .
- Input/output port 652 is coupled to local user interface 10 .
- Input/output port 654 is coupled to remote user interface 608 .
- Local user interface 10 provides a portion of the user interface for a user of alignment device 1 to control the operation of device 1 .
- local user interface 10 may include an alphanumeric keypad or cursor control device, such as a mouse, trackball, stylus, or cursor direction keys. Information provided by the user through local user interface 10 is provided to controller 628 through input/output port 652 .
- Remote user interface 608 enables a user to communicate with alignment device 1 using remote control 621 —allowing the user to provide instructions.
- Remote user interface 608 supports the protocol required for facilitating a communications link with remote control 621 —providing conversions between the digital signaling of control subsystem 624 and the signaling of remote control 621 .
- one type of remote control communicates with remote user interface 608 through a radio frequency connection.
- Another type of remote control communicates with remote user interface 608 via an infrared signaling connection.
- U.S. Pat. No. 5,680,208 and U.S. Pat. No. 5,903,345 provide examples of remote controls and remote control interfaces that can be used with alignment device 1 .
- U.S. Pat. No. 5,680,208 and U.S. Pat. No. 5,903,345 are hereby incorporated by reference.
- control subsystem 624 may include a display system and a communications controller.
- a display system enables alignment device 1 to display textual and graphical information.
- the display system may include a cathode ray tube (CRT) display or liquid crystal display (LCD).
- CTR cathode ray tube
- LCD liquid crystal display
- the display system would receive textual and graphical information from controller 628 through input/output block 644 .
- Potential communications controllers include network interface cards or integrated circuits for interfacing alignment device 1 to a communications network. Instructions for enabling control subsystem 624 to perform processes may be down loaded into memory 630 over the communications network.
- control subsystem 624 only shows one embodiment of control subsystem 624 and that numerous variations of control subsystem 624 fall within the scope of the present invention.
- the components contained in control subsystem 624 are those typically found in general purpose computer and control systems, and in fact, these components are intended to represent a broad category of such computer components that are well known in the art.
- FIG. 14 provides one implementation of a process performed by alignment device 1 to bring output beam 8 into a position parallel to true level. This process is performed when alignment device 1 is positioned as shown in FIG. 1.
- Level sensor interface 639 receives a level indication from level sensor 80 (step 700 ).
- Control subsystem 624 determines whether the level indication identifies output beam 8 as parallel to true level (step 702 ). In one embodiment, this determination is made using the current values provided by level sensor 80 , as described above. If output beam 8 is level, the process in done. Otherwise, control subsystem 624 determines an appropriate level adjustment to move output beam 8 to the desired position (step 704 ). In one implementation, this determination is also made using current values from level sensor 80 .
- Control subsystem 624 then issues control signals for one or more of alignment motors 54 and 74 to reposition optics mounting assembly 24 (step 706 ). After the signals are issued, the above described process is repeated.
- control subsystem 624 directs the operation of motors 54 and 74 one at a time to limit the amount of current drawn by alignment device 1 .
- control subsystem 624 achieves small motor movements by giving a motor a first pulse in a first direction and a larger second pulse in a second direction opposite to the first direction. This results in the motor moving in the second direction.
- the second pulse is 4 to 16 times larger than the first pulse, resulting in stepped movements in the second direction of one seventy-fifth of a full motor shaft rotation.
- FIG. 15 shows one process for alignment device 1 to give output beam 8 a desired angular offset from true level.
- Control subsystem 624 first brings output beam 8 to true level as described above with reference to FIG. 14. Once output beam 8 is level (step 702 ), control subsystem 624 determines an offset adjustment to make to optics mounting assembly 24 , using motors 54 and 74 (step 712 ). Control subsystem 624 issues control signals for motors 54 and 74 in accordance with the determination made in step 712 (step 714 ). If the offset is correct the process is done. Otherwise, the process can be performed again starting with the leveling operation (step 716 ).
- lead screws 46 and 66 have encoders mounted thereon to provide control subsystem 624 with the position of lead screws 46 and 66 .
- Control subsystem 624 correlates encoder intervals to the angular movement of output beam 8 to determine the magnitude of lead screw rotation required to achieve a desired angular offset (step 712 ).
- level sensor 80 facilitates the operation of a bump sensor.
- bubble 235 in level sensor 80 undergoes a momentary change, such as a rapid change in position.
- Level sensor 80 sends signals identifying this change to control subsystem 624 .
- control subsystem 624 ceases rotation of reflector 96 , reduces or eliminates the power of output beam 8 , and levels alignment device 1 as disclosed above with reference to FIG. 14.
- FIG. 16 shows one embodiment of a process for aligning output beam 8 when alignment device 1 is rotated ninety degrees from the position shown in FIG. 1 to produce vertical references.
- tilt sensor 600 recognizes the rotation of device 1 and issues a signal.
- control subsystem 624 sets lead screws 46 and 66 to a predetermined position (step 800 ).
- control subsystem 624 directs motors 54 and 74 to fully extend each lead screw.
- Control subsystem 624 detects full extension from a pair of sensors (not shown) that provide signals upon coming into contact with lead screws 46 and 66 .
- control subsystem directs motors 54 and 74 to position pads 42 and 62 at a predetermined position.
- lead screws 42 and 62 are translated to positions that correlate to a predetermined number of motor pulses.
- encoders are mounted on screws 42 and 62 to correlate screw translation to motor pulses.
- a user looks at bubble level 90 to determine whether optics mounting assembly 24 is leveled—the central axis of optics mounting system being parallel to true level (step 802 ). If bubble level 90 signals a level, the process in done (step 804 ). Otherwise, the user employs local interface 10 or remote control 621 to direct control subsystem 624 to determine a new level adjustment (step 806 ). In one embodiment, the user indicates a number of desired lead screw turns, and control subsystem 624 determines the required signal to make motors 54 and 74 carry out the user defined action (step 806 ). Control subsystem 624 then issues the determined signals to motors 54 and 74 (step 808 ). The above-described process in then repeated starting with step 802 . In alternate embodiments, the user provides different forms of data to specify lead screw movement, such as the time period a control button is pressed.
- FIG. 17 shows a process for positioning output beam 8 when alignment device 1 is rotated as described with reference to FIG. 16. This can be useful when a user wants to translate a vertical laser plane from output beam 8 on an incident surface.
- the leveling process described in FIG. 17 is performed.
- an offset adjustment is determined (step 810 ) for achieving a desired yaw.
- a user employs local interface 10 or remote control 621 to indicate a magnitude of movement desired from lead screws 46 and 66 .
- lead screws 46 and 66 are moved in opposite directions to achieve an output reference translation, while maintaining an orthogonal vertical laser plane or line.
- Control subsystem 624 converts the user's input into signals that will drive motors 54 and 74 . Control subsystem 624 then issues these signals for motors 54 and 74 (step 812 ). If the resulting output reference position is correct, the process is done (step 814 ). Otherwise, the process is repeated starting at step 810 .
- the user looks at bubble vial 90 and the incident laser beam output to determine if the resulting output beam repositioning is correct. In alternate embodiments, the process shown in FIGS. 16 and 17 are fully automated.
- alignment device 1 operators select the location of reference lines and points by providing a location input through remote control 621 or local user interface 10 —causing optics motor 108 to rotate penta-prism 96 into a desired position for a reference point or line. In the case of a reference line, motor 108 also dithers shaft 98 between two positions to create a line on an incident surface.
- Alignment device 1 includes a motor control mechanism that enables operators to accurately position optics motor 108 when selecting reference line and point locations.
- motor 108 is a direct drive motor, such as the motors used in compact disc players.
- FIG. 18 shows a process employed by alignment device 1 to position optics motor 108 .
- Device 1 controls motor 108 by providing a control signal. The pulse width and frequency of the control signal determine the magnitude of rotation of optics motor 10 .
- Optics motor 108 is first calibrated to identify an ideal pulse width for use in motor 108 (step 960 ).
- device 1 determines the motor control signal necessary for positioning motor 108 to a desired position (step 962 ) and provides the signal to motor 108 (step 964 ).
- One implementation steps for performing the process shown in FIG. 18 us found in U.S. patent application Ser. No. 09/928,244, which is incorporated herein by reference.
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Abstract
Description
- This Application is related to the following applications:
- U.S. patent application Ser. No. 09/928,244, entitled “Laser Alignment Device Providing Multiple References,” filed on Aug. 10, 2001 and
- U.S. patent application Ser. No.10/004,694, entitled “Servo-Controlled Automatic Level and Plumb Tool,” filed on Dec. 4, 2001.
- This Application incorporates each of the above-identified applications herein by reference.
- This application claims the benefit under 35 U.S.C. §120 of, and is a continuation-in-part of, U.S. patent application Ser. No. 10/004,694, entitled “Servo-Controlled Automatic Level and Plumb Tool,” filed on Dec. 4, 2001, which is incorporated herein by reference.
- 1. Field of the Invention
- The present invention is directed to the field of alignment devices.
- 2. Description of the Related Art
- People undertaking construction and repair projects frequently require the use of reference guides. People employ reference guides on projects ranging from professional construction of large city buildings to amateur home improvement. For example, a person installing a border on the walls of a room requires a level reference line on each wall identifying a placement position for the border.
- Traditional alignment tools for assisting in the manual placement of reference guides include straight edges, rulers, protractors, squares, levels, and plumb bobs. More recently, tool manufacturers have introduced laser alignment devices that provide references, such as points, lines, and planes. These laser alignment tools include, simple pointers, pointers with bubble vials, self-leveling pointers, multiple beam pointers, and devices producing a sheet of light.
- In many instances a project requires the use of multiple references. For example, a project may require the use of both reference lines and planes in horizontal and vertical orientation. In many instances this requires the use of multiple alignment tools—forcing a person to have all of these tools available for the project. The purchase, maintenance, storage, and transportation of several alignment tools are undesirable inconveniences that consume time and money. In some circumstances it is simply impractical to have multiple alignment tools readily available on a job site.
- It is desirable for a single alignment tool to provide multiple types of references in both horizontal and vertical orientations. This reduces the number of tools required for a job—allowing users the convenience of purchasing, maintaining, storing, and transporting a reduced number of tools. The user's convenience in using a multiple reference tool, however, must not be outweighed by the expense of the tool. The multiple reference alignment tool also needs to meet the user's accuracy expectations.
- In electromechanical control systems, such as an automated reference tool, backlash can be a leading source of inaccuracy. In a control system, the movement of a first object directs the motion of a second object. Backlash is the phenomenon of mechanical hysteresis that occurs when the direction of motion of the first object is altered. Mechanisms controlling the motion of the second object by directing the motion of the first object need to account for backlash. Otherwise, the control system's accuracy will be compromised. A multiple reference alignment tool needs to either reduce or compensate for backlash in all of the orientations the tool will be used.
- Traditional systems frequently employ expensive high precision components to overcome the problem of backlash and minimize other sources of inaccuracy. However, this can result in increasing the expense of a reference tool beyond the acceptable threshold of many users. It is desirable to reduce backlash effects and other inaccuracies without necessitating the use of expensive components.
- The present invention, roughly described, pertains to an alignment device capable of providing multiple references in different orientations—reducing the number of alignment devices a user needs for a job site. One implementation of the alignment device provides a horizontal set of laser references and a vertical set of laser references. For each set of references, users have the ability to select a plane, line, or pointing reference. In one version of the alignment device, users can also rotate the position of the vertical and horizontal reference points and lines. In a further embodiment, users can adjust the positions of the laser planes on incident surfaces.
- One embodiment of the alignment device includes an optics mounting assembly mounted in a pivot socket on a frame. A spring system and one or more alignment assemblies secure the optics mounting assembly in the pivot socket. The optics mounting assembly includes a light source supplying a light beam. In one embodiment, the light source is a laser emitting diode supplying a laser beam. The source beam is incident on a reflector that produces an output reference beam. At rest, the reflector produces a reference point. A motor mounted on the optics mounting assembly spins the reflector to generate a reference plane. The motor dithers the reflector to generate a reference line. In a further embodiment, a user can manually position the output reference beam.
- One implementation of the pivot socket has a surface in the form of a sphere's interior surface. The optics mounting assembly extends through the pivot socket and includes a set of support members that rest on the pivot socket's spherical surface. The support members hold the reflector in a position that results in the output reference beam originating at the center of a sphere that includes the pivot socket's spherical surface. This minimizes translation of the output reference beam's origin when the optics mounting assembly pivots in the socket.
- The spring system includes a set of one or more springs exerting force on the optics mounting assembly. The spring force pulls the optics mounting assembly support arms against the spherical surface of the pivot socket. The spring force also attempts to rotate the optics mounting assembly about a pivot point at the center of a sphere that includes the spherical surface of the socket. The optics mounting assembly includes a set of extension arms that communicate with the alignment assemblies. The alignment assemblies apply forces on the extension arms that oppose the rotation induced by the spring force—holding the optics mounting assembly in a desired position within the pivot socket.
- Alignment assembly movements direct the movement of the optics mounting assembly—altering the position of the output reference beam. In one embodiment, the alignment device includes a level sensor that supplies signals indicating whether the optics mounting assembly is normal to true level. A control subsystem in the alignment device employs these signals to drive the alignment assemblies. The alignment assemblies provide forces to the optical mounting assembly extension arms—positioning the optics mounting assembly normal to true level. This results in an output reference beam parallel to true level.
- The spring system assists in removing backlash from the alignment device's controlled movement of the optics mounting assembly. The spring system holds the extension arms flush against pads on the alignment assemblies. The optics mounting assembly support arms are held flush against the spherical surface of the pivot socket by the combined forces of the (1) alignment assemblies on the extension arms and (2) the spring system on the optics mounting assembly.
- In one implementation, each alignment assembly pad is mounted on a lead screw with a gear driven by a motor controlled pinion. The pinion's teeth are tightly coupled to the gear's teeth to further reduce backlash. The pinion and gear are drawn together by a spring force that allows the gear and pinion teeth to separate, as needed, to minimize backlash and compensate for run-out.
- The alignment device also produces an accurate reference beam when the device is rotated by ninety degrees—converting a horizontal laser plane generated by the reference beam into a vertical laser plane. The spring system and alignment assemblies provide the same forces in the rotated orientation to secure the position of the optics mounting assembly and remove backlash effects. In such an implementation, the alignment assemblies can be employed to control the positioning of the output reference beam on an incident surface. For example, the alignment assemblies may horizontally translate a vertical laser plane output on the incident surface.
- Further implementations of the alignment device include additional features for enhancing accuracy. For example, the reflector can be a penta-prism mounted with a predefined pitch for reducing the effects of satellite output beams. The penta-prism may also include a predetermined pitch deviation. The penta-prism is then mounted within a known roll range to achieve a more accurately positioned reference beam.
- Alignment devices in alternate embodiments of the present invention may provide less than all of the references described above. One version of an alignment device according to the present invention only provides a single type of reference in a single orientation.
- Aspects of the present invention can be accomplished using hardware, software, or a combination of both hardware and software. The software used for the present invention is stored on one or more processor readable storage media including hard disk drives, CD-ROMs, DVDs, optical disks, floppy disks, tape drives, RAM, ROM or other suitable storage devices. In alternative embodiments, some or all of the software can be replaced by dedicated hardware including custom integrated circuits, gate arrays, FPGAs, PLDs, and special purpose computers.
- These and other objects and advantages of the present invention will appear more clearly from the following description in which the preferred embodiment of the invention has been set forth in conjunction with the drawings.
- FIG. 1 depicts the exterior of an alignment device in one embodiment of the present invention.
- FIGS.2A-2B show perspective views of internal components in one version of the alignment device in FIG. 1.
- FIG. 2C shows a front view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2D shows a rear view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2E shows a perspective bottom view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2F shows a bottom view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2G shows a top view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2H shows a side view of internal components in one version of the alignment device in FIG. 1.
- FIG. 2I shows a cross-sectional side view of internal components in one version of the alignment device in FIG. 1.
- FIG. 3 is a side-section view of one implementation of a dual axis level sensor.
- FIG. 4 is a perspective view of an implementation of a dual axis level sensor.
- FIG. 5 depicts an embodiment of a quadrature detector in accordance with the present invention.
- FIGS. 6 and 7 are side-section views of additional level sensor embodiments in accordance with the principles of the present invention.
- FIG. 8 shows a cross-sectional view of a jack screw assembly mounting a laser sensor to an optics mounting assembly in one embodiment of the present invention.
- FIG. 9 shows a penta-prism used in one embodiment of the present invention as a reflector.
- FIGS.10A-10C shows alternate embodiments of a penta-prism and implementations for mounting a penta-prism.
- FIGS.11A-11B show various perspective views of one embodiment of a rotation cap for use in the alignment device shown in FIG. 1.
- FIG. 12 shows a perspective view of the spring mechanism in the rotation cap shown in FIGS.11A-11B.
- FIG. 13 is a block diagram for one implementation of a control subsystem for the alignment device in FIG. 1.
- FIG. 14 is a flowchart describing one implementation of a process for leveling a horizontal reference.
- FIG. 15 is a flowchart describing one implementation of a process for setting a horizontal reference to a predetermined offset.
- FIG. 16 is a flowchart describing one implementation of a process for leveling a vertical reference.
- FIG. 17 is a flowchart describing one implementation of a process for setting a vertical reference to a predetermined offset.
- FIG. 18 is a flowchart describing one version of a process for positioning horizontal and vertical references.
- I. External Operation
- FIG. 1 shows a
laser alignment device 1 in accordance with the present invention.Output beam 8 emanates from beam turret 4, which is mounted on top ofalignment device 1. In one embodiment,output beam 8 is a laser beam, while in alternateembodiments output beam 8 can be any type of light, including visible and invisible light.Alignment device 1 usesoutput beam 8 to provide reference points, lines, and planes on incident surfaces. In the orientation shown in FIG. 1,alignment device 1 provides horizontal reference lines and planes. Whenalignment device 1 is rotated by ninety degrees,output beam 8 provides vertical reference lines and planes. The rotated operation ofalignment device 1 is described below in greater detail. - The position of
output beam 8 can be rotated to adjust the position of a reference line or point. In one embodiment, a user manually rotatesrotation cap 6 on turret 4 to make an angular adjustment to the position of aoutput beam 8. In an alternate embodiment,alignment device 1 automates the angular adjustment ofoutput beam 8. -
Local interface 10 onalignment device 1 includes control buttons that enable users to control the operation ofalignment device 1. This allows users to generate and position horizontal and vertical references. In an alternate implementation,alignment device 1 includes a remote control receiver (not shown). The remote control receiver enables communication with a remote control, so a user can remotely direct the operation ofalignment device 1. One skilled in the art will recognize that such a remote control receiver can support any one of a number of different communication mediums and protocols. For example, in one embodiment, the remote control receiver supports radio frequency communication, while in another embodiment the receiver supports infrared signaling. - II. Internal Component Operation
- A. Optics Alignment
- FIGS.2A-2I show one implementation of internal components for
alignment device 1 in accordance with the present invention. FIGS. 2A-2I show different views as described above. - As shown in FIG. 2I,
laser source 116 is mounted in mounting device 117, which is press fit into the hollow main shaft ofoptics mounting assembly 24. In one embodiment,laser source 116 is a laser emitting diode coupled tocircuit board 120, and mounting device 117 is a mounting joint, as described in U.S. patent application Ser. No. 09/928,244.Collimating lens 134 is mounted inmount fixture 102, which is fitted into the main shaft ofoptics mounting assembly 24 in line withlaser source 116. -
Optics mounting assembly 24 houseshollow rotation shaft 98, which extends through guide rings 130 and 132. Withinoptics mounting assembly 24, rotatingsupport ring 106 supportsrotation shaft 98 in line withcollimating lens 134.Shaft 98 supports reflector 96 in line withlens 134 andlaser source 116. A laser beam fromsource 116 extends throughlens 134 and ontoreflector 96, which converts the beam fromsource 116 intooutput beam 8. -
Motor 108 onoptics mounting assembly 24 drives the rotation ofsupport ring 106 to rotateshaft 98.Shaft 112 frommotor 108 is coupled tobelt drive gear 114.Belt 104 extends aroundsupport ring 106 andgear 114. In operation,motor 108 rotatesshaft 112, which rotatesgear 114. The rotation ofgear 114 drivesbelt 104 to rotatesupport ring 106—resulting in the rotation ofoutput beam 8. As will be described in more detail below, a control subsystem inalignment device 1 employsmotor 108 to perform the following operations: 1) spinningreflector 96 to generate a laser plane reference; 2) ditheringreflector 96 to generate a partial laser plane reference; and 3) adjusting the rotation ofreflector 96 to position a laser reference point.Encoder 110 is mounted onshaft 112 to facilitate dithering and pointing. -
Alignment device 1 sets and secures the position ofoptics mounting assembly 24, so thatoutput beam 8 has a desired orientation with respect to true level. In one embodiment,alignment device 1 provides foroptics mounting assembly 24 to produceoutput beam 8 as parallel to true level. In further embodiments,alignment device 1 stabilizesoptics mounting assembly 24 to have a predetermined offset from true level. - Looking at FIGS. 2A and 2B,
optics mounting assembly 24 extends throughpivot socket 22 on frame 20.Optics mounting assembly 24 includessupport members section 23 ofpivot socket 22.Section 23 is formed in the shape of a section from an interior surface of a sphere.Spherical section 23 extends downward fromrim 26 onsocket 22, which is used to mountsocket 22 to frame 20. In an alternate embodiment,pivot socket 22 is formed in housing 20.Alignment device 1 adjusts the position ofoptics mounting assembly 24 withinpivot socket 22 to give output beam 8 a desired orientation, such as parallel to true level. - In one implementation,
members optics mounting assembly 24, so thatoutput beam 8 originates fromreflector 96 at a point in the center of a sphere includingspherical section 23. This center point also serves as the pivot point forassembly 24. This eliminates translation of the output beam origin whenalignment device 1 adjusts the position ofoptics mounting assembly 24 withinpivot socket 24. In alternate embodiments, the origin ofoutput beam 8 may deviate from the sphere center point. In further embodiments,section 23 can have a non-spherical surface. -
Optics mounting assembly 24 includesextension arms extension arms optics mounting assembly 24. In one implementation,extension arms optics mounting assembly 24 perpendicular to each other. - Alignment assemblies within
alignment device 1 provide adjustment forces toextension arms extension arm 36 includesmotor 54, which rotates shaft 52.Pinion 50 is mounted on shaft 52 and has teeth in communication with teeth ongear 48. Leadscrew 46 is mounted to gear 48, so thatscrew 46 rotates whengear 48 rotates. Leadscrew 46 extends throughlead nut 44, so thatlead nut 44 translates alonglead screw 46, based on the direction that screw 46 rotates.Alignment force pad 42 is coupled tonut 44, so thatpad 42 follows the translation path ofnut 44. In one embodiment,pad 42 includesinterface contact 141 to communicate withextension arm 36. (See FIG. 2C.) In one such embodiment, contact 141 has a spherical surface that enhances the ability ofpad 42 to moveextension arm 36 without binding. - In one implementation, the teeth of
pinion 50 are tightly interlocked with the teeth ofgear 48 to reduce backlash in the operation of the alignment assembly. As seen in FIG. 2H,gear 48 andpinion 50 are held in communication byspring 150—reducing backlash and compensating for run-out.Spring 50 reduces backlash by pulling the teeth ofgear 48 andpinion 50 tightly together in operation.Spring 50 also reduces run-out. In this implementation,motor mount 152 supportsmotor 54.Motor mount 152 is mounted to frame 20 so thatmount 152 can pivotpinion 50 away from and towardgear 48.Spring 150 is coupled tomotor mount 152 and frame 20 to facilitate the above-described operation between the teeth ofgear 48 andpinion 50. - An alignment assembly in communication with
extension arm 34 includesmotor 74, which rotatesshaft 72.Pinion 70 is mounted onshaft 72 and has teeth in communication with teeth ongear 68. Lead screw 66 is mounted to gear 68, so that screw 66 rotates whengear 68 rotates. Lead screw 66 extends through lead nut 64, so that lead nut 64 translates along lead screw 66, based on the direction that screw 66 rotates.Alignment force pad 62 is coupled to nut 64, so thatpad 62 follows the translation path of nut 64. In one embodiment,pad 62 includesinterface contact 140 to communicate withextension arm 34. In one such embodiment, contact 140 has a spherical surface that enhances the ability ofpad 62 to moveextension arm 34 without binding. - In one implementation, the teeth of
pinion 70 are tightly interlocked with the teeth ofgear 68 to reduce backlash in the operation of the alignment assembly.Gear 68 andpinion 70 are held in communication by spring 160 (not shown, but operating like spring 150) to reduce backlash and compensate for run-out. Spring 160 reduces backlash by pulling the teeth ofgear 68 andpinion 70 tightly together in operation. Spring 160 also reduces run-out effects. In this implementation,motor mount 162 supportsmotor 74.Motor mount 162 is mounted to frame 20 so thatmount 162 can pivotpinion 70 away from and towardgear 68. Spring 160 is coupled tomotor mount 162 and frame 20 to facilitate the above-described operation between the teeth ofgear 68 andpinion 70. - A spring set in
alignment device 1 pullsoptics mounting assembly 24 intopivot socket 22 and directsextension arms pads - As seen in FIGS.2A-2C, the spring set has
springs Springs optics mounting assembly 24.Springs support member spherical section 23 ofpivot socket 22. The forces fromsprings optics mounting assembly 24 to rotate about a pivot point at the center of a sphere includingspherical section 23—pullingextension arms pads pads extension arms optics mounting assembly 24 in place. - The combined forces from
springs alignment assembly pads alignment device 1. These forces ensure thatsupport member spherical section 23 andextension arms pads alignment device 1 adjusts the position ofoutput beam 8 by using the alignment assemblies to adjust the position ofoptics mounting assembly 24. The lag time between drivingmotors extension arms pads arms - Ideally, springs38 and 40 are constant force springs that exert constant forces regardless of how far they are stretched. In an alternate embodiment, the spring force of
springs extension arms pads assembly 24 insocket 22. In one implementation, these constraints are met for the entire allowed range of motion forassembly 24, including the rotated position ofalignment device 1 to produce a vertical reference plane as described herein. In an additional implementation, springs 38 and 40 do not contactassembly 24, except in the points where springs 38 and 40 are anchored toassembly 24. - In a further implementation,
extension arms arms screws 46 and 66 causes the fine leads to slide up or downscrews 46 and 66, based on the direction of rotation causing the position ofoptics mounting assembly 24 inpivot socket 22 to be adjusted. The fine lead embodiment also reduces backlash effects, since the leads rest directly on the grooves inscrews 46 and 66. In one embodiment, the fine leads are cylindrical and rigid with the dimensions of standard piano wire. In one example, the fine lead diameter is 1 millimeter or less. - Using the fine leads enables lead screws44 and 46 to be driven directly by a motor, without the need for a gear and pinion mechanism.
Screws lead nuts 44 and 64 andpads - In another embodiment, a surface on either
arm 34 orarm 36 that contacts pad 62 orpad 42 has a groove (not shown). The groove receives the respectivespherical contact arms - In yet another embodiment of the present invention,
optics mounting assembly 24 is replaced by a pendulum assembly that supports the above-described optical elements, including a motor for rotatingreflector 96. In one such embodiment, the pendulum base includes shafts that support one or more balancing weights. The alignment assemblies are modified to slide the weights along the pendulum base shafts to adjust the pendulum's center of gravity. These adjustments modify the position ofoutput beam 8. - B. Level Sensor
- One version of
alignment device 1 also has the capability to self-level—automatically bringingoutput beam 8 into a parallel relationship with true level. As shown in FIGS. 2A-2I,level sensor 80 is mounted tooptics mounting assembly 24 to determine whether the central axis ofassembly 24 is normal to true level.Level sensor 80 provides level indicators to a control subsystem inalignment device 1. In response to the level indicators, the control subsystem drivesmotors optics mounting assembly 24 into a perpendicular relationship with true level. Example embodiments oflevel sensor 80 are disclosed in U.S. patent application Ser. No. 10/004,694. - FIGS.3-7 show various implementation of
level sensor 80. FIG. 3 showsdetector element 230 inlevel sensor 80, including positionsensitive photo sensor 231, two-axis bubble level 232,aperture structure 229, anddetector light source 233 for generating detector light beam 234 (also referred to as detector light).Detector light 234 is passed throughbubble level 232 onto positionsensitive photo sensor 231, which detects whetherbubble level 232 is leveled. Since the illustrated embodiment is tiltable in two degrees of freedom, a detector (e.g. bubble level) that is sensitive to tilting in two degrees of freedom is particularly appropriate. In other embodiments, an angled pair of one-dimensional tilt detectors may be used. It is to be noted that other embodiments of detector elements can be used in accordance with the principles of the present invention. - When
bubble 235 is centered inlevel 232, the output beams are level. Asbubble level 232 is tilted,bubble 235 moves from a centered position. This alters the position and amount oflight 238 being detected by positionsensitive photo sensor 231. In order to more quickly centerbubble 235,bubble level 232 can include acurved bubble face 236. In one embodiment,curved bubble face 236 has a radius of curvature of 70 millimeters. Positionsensitive photo sensor 231 can incorporate any of a number of commercially available position sensitive detectors sensitive todetector light 234. Examples include, but are not limited to, quadrature detectors, charged coupled device (CCD) detectors, complementary metal oxide semiconductor (CMOS) image sensors (such as that taught in U.S. Pat. No. 5,461,425 to Fowler, et al. hereby incorporated by reference). - FIG. 4 is a perspective view of an embodiment of a two-
axis detector element 230 in accordance with the principles of the present invention.Light source 233 generates a beam that passes through aperture 229 (See FIG. 3) to producedetector light beam 234 that is directed through two-axis bubble level 232 ontoquadrature detector 231. Detector light 234 passes readily throughfluid 237 but is refracted in large part bybubble 235 of two-axis bubble level 232. Consequently,detector light 234 forms ring oflight 238 surroundingdark spot 239.Ring 238 andspot 239 track the movement ofbubble 235 as detector element 230 (and by consequence the output beams) is tilted. Whendark spot 239 is centered in the middle ofquadrature detector 231,output beam 8 is level. Therefore, whendark spot 239 is not centered onquadrature detector 231, adjustments are made to the alignment ofoptics mounting assembly 24 untildark spot 239 is centered. In alternate embodiments,bubble 235 is replaced by another object to castring 238 andspot 239. Whenbubble 235 is replaced by an object with a different shape, the shapes ofring 238 and spot 239 change accordingly. - Adjustments are accomplished by selective activation of the alignment assemblies, until
dark spot 239 is centered. This is accomplished via a control subsystem indevice 1 that adjusts the position of optical mountingassembly 24 in response to information received fromquadrature detector 231. Bubble detector embodiments can be constructed such that the inside walls of the bubble container are not easily wetted by the fluids contained therein. In one example, the fluid can be water and the inside surface of the bubble container can be treated with hydrophobic material. - FIG. 5 depicts an embodiment of
quadrature detector 231 featuringdark spot 239 andlight ring 238. Such an embodiment is suitable for use in accordance with the principles of the present invention. As can be seen,quadrature detector 231 is fully illuminated withinring 238 except fordark spot 239. As the sensor is tilted,dark spot 239 moves with respect toquadrature detector 231. By tracking the motion ofdark spot 239,quadrature detector 231 provides leveling information. The detector element is calibrated so that the output beams are leveled whendark spot 239 is centered inquadrature detector 231. -
Quadrature detector 231 has fourphotodetectors light ring 238 impinges on the photodetectors of the quadrature detector, electrical current is produced. The magnitude of the current bears a relationship to the intensity of the light impinging onphotodetectors dark spot 239. The control subsystem indevice 1 measures the current produced by the photodetectors and processes the current to determine the location ofdark spot 239 onquadrature detector 231. Typically, the current produced by the photodetectors is conducted away from the detector usingconductive lines 240, which can be connected to the control subsystem ofdevice 1. The current fromphotodetectors spot 239 position is as follows: In order to determine the left/right (L/R) position of thespot 239, current I241 produced fromphotodetector 241 is summed with current I243 produced byphotodetector 243, and current I242 produced byphotodetector 242 is summed with current I244 producedphotodetector 244. The two sums are normalized and subtracted from each other as shown in the equation below. - [(I241+I243)−(I242+I244)]/(I241+I243+I242+I244)=L/R Position Current
- If the L/R position current is negative, it is known that
spot 239 is too far to the left. And, conversely, if the L/R position current provides a positive value, it is known thatspot 239 is too far to the right. - The up and down positions of the spot can also be determined with
quadrature detector 231. For example, in accordance with the following equation: - [(I241+I242)−(I243+I244)]/(I241+I243+I242+I244)=Up/Down Position Current
- If the up/down position current is positive,
spot 239 is too low. Conversely, if the up/down position current is negative, then spot 239 is too high. If the depictedspot 239 is used as an example, the left/right position current will be negative and the up/down position current will be positive, which will allow the control subsystem to detect the fact that the beam is in the quadrant detected byphotodetector 243. Based on this information, the alignment assemblies are activated to adjust the position ofoptics mounting assembly 24 in order to movedark spot 239 higher and to the right to level the bubble, thereby levelingoutput beam 8. - In another embodiment, light ring238 (and dark spot 239) can be generated by a plurality of laser emitting diodes (LED's). Once the device is leveled, the brightness of each of these LED's can be adjusted until
dark spot 239 is centered onlight detector 231. This is advantageous because it can be accomplished electronically without the need for costly and time consuming alignment steps. Instead, simple adjustment of LED brightness can be used to center the dark spot 139 in a calibration step. One such embodiment can use four LED's. - FIG. 6 depicts the operation of yet another
sensor embodiment 250. The sensor element is depicted in a cross-section view.Sensor element 250 includes positionsensitive photo sensor 281,bubble level device 252,aperture structure 279, anddetector light source 283 for generating detector light beam 284 (also referred to as detector light). As with the previously discussed embodiments, many different types of detectorlight sources 283 can be used, such as LED's.Detector light 284 is passed throughbubble level device 252 onto positionsensitive photo sensor 281, which detects whetherbubble level device 252 is leveled (as is the case in FIG. 6). In the depicted embodiment,bubble fluid 253 is treated so that it is relatively opaque todetector light 284. For example, a dye can be added tobubble fluid 253, so that a portion of the detector light passes throughbubble level device 252 in the region ofbubble 255, but not throughfluid 253. In other words,detector beam 284 passes readily throughbubble 255 ofbubble level 252, but is absorbed byfluid 253. As a result,detector light beam 256exits bubble level 252. Unlike the forgoing embodiments, where the detector beam is ring-shaped, thisdetector light beam 256 is characterized by a light spot defined bybubble 255. As with the previous embodiments,sensor 250 can be oriented so thatbeam 284 points downward. - FIG. 7 shows
detector 250 tilted to the left. Consequently,bubble 255 moves to the right, altering the amount and position of light 256 sensed by positionsensitive photo sensor 281. In accordance with the principles of the present invention, positionsensitive photo sensor 281 provides information to control circuitry (not shown here) which activates the alignment assemblies to correct the tilt inoutput beam 8. - The position sensitive photo detectors work similarly to those described hereinabove. The chief difference being that the electrical information is processed by the photo detectors in a slightly different manner to track the light spot as it moves across the photo detectors. Such methods are known to those having ordinary skill in the art. In a further embodiment, invisible light can be employed in
level sensor 80. - Another suitable detector element embodiment can use a pair of single-axis bubble levels arranged at right angles to each other so that a level with respect to a first and second axis can be detected. Each single-axis bubble level is associated with a corresponding light source and a corresponding position sensitive detector. Each corresponding light source and corresponding position sensitive detector is arranged to detect whether each single-axis bubble level is leveled. By leveling each single-axis bubble level, the output beams can be leveled with respect to the aforementioned first and second axes.
- C. Level Sensor Mounting
- As shown in FIG. 2C,
screw assemblies mount level sensor 80 tooptics mounting assembly 24. FIG. 8 shows a cross-sectional view of one embodiment ofscrew assembly 84, which can also be used forscrew assemblies member 300 extending fromoptics mounting assembly 24 andmember 302 extending fromlevel sensor 80. Taking stress off ofmember 300 is particularly beneficial, so that the chance of destabilizingoptics mounting assembly 24 is reduced. -
Jack screw 312 has a threaded segment that extends into threadedchannel 320 inmember 300.Screw 306 extends throughBellville washer 308,washer 310, unthreadedchannel 322 injack screw 312, and threadedchannel 324 inmember 302.Jack screw 312 rests onmember 302, so thatchannel 322 injack screw 312 is in line withchannel 324 inmember 302. Rotatingjack screw 312 either pullsmembers members channel 322 injack screw 312.Rotating screw 306 either pullsmembers members screw 306. -
Washer 308 is fitted under the head ofscrew 306, so that the surface ofwasher 308 extends downward from an interior circumference to an exterior circumference. This causes the exterior circumference ofwasher 308 to apply a force toward the surface ofmember 300. This force takes pressure off ofmember 300 whenscrew 306 is not fully tightened. Without the force fromwasher 308,member 300 would tend to pull against the holding force applied byjack screw 312—creating strain inmember 300. This feature can be useful in the manufacturing process ofalignment device 1, beforescrew 306 is fully tightened so thatwasher 308 is driven to be flat likewasher 310. - D. Optical Reflector Assemblies
- FIG. 9 illustrates five-sided penta-prism400, which can be employed to operate as
reflector 96. Penta-prism 400 produces an output beam perpendicular to a beam entering throughinput side 402. In operation,beam 410 enters penta-prism 400 throughside 402 and is reflected by mirroredsurface 404 to produce reflectedbeam 412. Mirroredsurface 406 reflectsbeam 412 to createoutput beam 8. In alternate embodiments,reflector 96 is implemented with objects other than a penta-prism. - FIGS.10A-10C show alternate embodiments for
reflector 96 and the mounting ofreflector 96. FIG. 10A shows penta-prism 420, which can be employed to operate asreflector 96. Penta-prism 420 generates output beam 429 in response toinput beam 421.Angle 426 is less than the ideal ninety degrees betweenbeams angle 426 is 5 arc-seconds less than ninety degrees. In further embodiments,angle 426 is designed with a tolerance of plus or minus 5 arc-seconds. The desired value ofangle 426 can be achieved in one embodiment by increasingangle 425, decreasingangle 427, or increasingangle 425 and decreasingangle 427. - The known decrease in
angle 426 is useful for aligning penta-prism 420, so thatoutput beam 8 is normal toinput beam 421. With a perfectly angled penta-prism, the alignment can be difficult, due to challenges in mountingreflector 96 onrotation shaft 98 with a zero roll alignment. A deviation in roll ofreflector 96 causesoutput beam 8 to have an incline—increasing the angle betweenoutput beam 8 andinput beam 421. A known deviation inangle angle 426 makes it acceptable to mount penta-prism 420 with a roll other than zero. The decrease inangle 426 is offset by deviations in the roll to moveoutput beam 8 closer to a perpendicular relationship with the input beam toreflector 96. In one embodiment,shaft 98 allowsreflector 96 to be mounted within plus or minus 0.1 degree of zero roll alignment. - FIG. 10B shows a cross-section of
shaft 98 in one embodiment for mounting an implementation ofreflector 96, such as penta-prism 420. This embodiment ofshaft 98 makes it easier to mount penta-prism 420 with a desired roll. The V-shaped groove at the top ofshaft 98 eliminates any roll effects that would be introduced by imperfections in the top surface ofshaft 98. The edges of penta-prism 420 are aligned on the groove surfaces and secured, so that penta-prism 420 has a roll within a desired tolerance. In one embodiment, penta-prism 420 is secured toshaft 98 with an epoxy. In one embodiment,shaft 98 allowsreflector 96 to be mounted within plus or minus 0.1 degree of zero roll alignment. - FIG. 10C shows an embodiment of
shaft 98 havingdecline slope 430 on the top surface. When penta-prism 420 is mounted on declinedshaft 98, the effects of satellite output beams are significantly reduced. In one implementation,decline angle 432 is offset two degrees from perpendicular. In an alternate implementation,decline angle 432 has a different value. In various embodiments, different penta-prisms can be employed, such as penta-prism 400 or penta-prism 420. The features ofshaft 98 in FIGS. 10B and 10C are both employed in some embodiments, while only one of the features or none of the features are employed in alternate embodiments. - In a further embodiment,
reflector 96 is partially transmissive, so that a second beam perpendicular tooutput beam 8 is generated. In alternate embodiments, different angular relationships tooutput beam 8 can be employed. In one implementation, penta-prism face rotation cap 6, a window or other opening can be formed incap 6. - E. Manual Rotation Cap
- FIGS. 11A and 11B show a perspective view of
rotation cap 6, which can be used to manually rotate the position ofreflector 96.Rotation cap 6 allows a user's manual rotation force to be applied, while any extraneous translation forces are ignored. As shown in FIG. 2I,rotation shaft 98 extends throughreflector rotation mount 94.Rotation mount 94 is coupled torotation shaft 98, so that the rotation ofmount 94causes shaft 98 to rotate.Mount 94 includesridge 124.Cap 100 is coupled toridge 124, so that rotation force applied to cap 100 causes rotation mount 94 to rotateshaft 98. -
Rotation cap 6 includes a spring controlled wheel assembly to limit the translational force applied to cap 100. FIG. 12 shows spring controlledwheel assembly 500 includingwheels Prongs secure axel 512 passing throughwheel 500.Prongs secure axel 514 passing throughwheel 502. When a user is not applying force torotation cap 6,axel 512 rests on the bottom surfaces ofprongs Axel 514 rests on the bottoms ofprongs - When a user presses down on
rotation cap 6,axels grooves cap 100. Whenwheels prongs axel 512 that causeswheel 500 to maintain contact withcap 100. Similarly, the top portions ofprongs axel 514 that causeswheel 502 to maintain contact withcap 100. The friction between the surface ofcap 100 and the surfaces ofwheels wheels cap 100, except for rotation about theirrespective axels cap 100 rotating in response to a rotation force applied torotation cap 6 whilecap 6 is depressed. This rotation ofcap 6 adjusts the position ofoutput beam 8 by rotatingshaft 98. In one embodiment, the wheel surfaces are rubber and the surface ofcap 100 is plastic. - For safety purposes, the intensity of
output beam 8 can be reduced during a manual rotation. In one implementation,laser output beam 8 is reduced to 20% of its normal intensity. In one embodiment,alignment device 1 reduces the intensity ofoutput beam 8 upon detecting thatlevel sensor 80 has a predetermined deviation from level. This operation is performed by the control subsystem detecting an out of level indication and reducing the intensity of the beam fromlaser source 116. In various embodiments, different methods can be employed to reduce the intensity ofbeam 8. In addition to reducing the intensity ofbeam 8, the control subsystem ceases all automated rotation ofrotation shaft 98 until a level orientation is re-established. This inhibits the generation of laser planes and dithered reference lines. - F. Producing Vertical References
- In order to produce vertical references, such as lines and planes, a user rotates
alignment device 1 by ninety-degrees. In one embodiment, the user rotatesalignment device 1, so thatarms optics mounting assembly 24 are directed towards the ground. To facilitate this orientation,alignment device 1 provides a bubble vial mounted to frame 90, as shown in FIGS. 2H and 2I. In the rotated position,bubble vial 90 is on the exposed top surface ofalignment device 1 for use by the user in adjusting the position ofoutput beam 8. In the embodiment shown in FIGS. 2A-2I, self-leveling is not provided in the rotated state. In alternate embodiment, self-leveling is provided in the rotated state. In the rotated orientation,spring optics mounting assembly 24 withinpivot socket 22. - III. Control Subsystem
- A. Architectural Overview
- FIG. 13 is a block diagram of
control subsystem 624 inalignment device 1, as well as,alignment motor interface 634,alignment motor interface 636,optics motor interface 638,level sensor interface 639,local user interface 10,tilt sensor 600, andremote user interface 608. -
Control subsystem 624 controls user interfaces toalignment device 1 and the operation of motors inalignment device 1.Control subsystem 624 includesbus 632coupling controller 628,data storage unit 626,memory 630, and input/output block 644.Controller 628 is a central processing unit used for executing program code instructions, such as a microprocessor or mircocontroller. In response to program code instructions,controller 628 retrieves and processes data and provides data and control signals. Input/output block 644,data storage unit 626 andmemory 630 are all coupled tobus 632 to exchange data and control signals withcontroller 628. -
Memory 630 stores, in part, data and instructions for execution bycontroller 628. If a process is wholly or partially implemented in software,memory 630 may store the executable instructions for implementing the process whenalignment device 1 is in operation.Memory 630 may include banks of dynamic random access memory, static random access memory, read-only memory and other well known memory components -
Data storage unit 626 provides non-volatile storage for data and instructions for use bycontroller 628. In software embodiments of the present invention,data storage unit 626 may store instructions executed bycontroller 628 to perform processes.Data storage unit 626 may, support portable storage mediums, fixed storage mediums or both -
Data storage unit 626 implements fixed storage mediums using a magnetic disk drive or an optical disk drive.Data storage unit 626 supports portable storage mediums by providing a portable storage medium drive that operates in conjunction with portable non-volatile storage mediums—enabling the input and output of data and code to and fromcontrol subsystem 624. Examples of portable storage mediums include floppy disks, compact disc read only memory, or an integrated circuit non-volatile memory adapter (i.e. PC-MCIA adapter). In one embodiment, instructions for enablingcontrol subsystem 624 to execute processes are stored on a portable medium and input to controlsubsystem 624 via a portable storage medium drive. - For purposes of simplicity, all components in
control subsystem 624 are shown as being connected viabus 632.Control subsystem 624, however, may be connected through one or more data transport mechanisms. For example,controller 628 andmemory 630 may be connected via a local microprocessor bus, anddata storage unit 626 and input/output block 644 may be connected via one or more input/output (I/O) busses. - Input/
output ports output block 644couple bus 632 toalignment motor interface 634,alignment motor interface 636,optics motor interface 638,level sensor interface 639,local user interface 10,tilt sensor 600, andremote user interface 608, respectively.Alignment motor interface 634 is coupled toalignment motor 74.Alignment motor interface 636 is coupled toalignment motor 54.Optics motor interface 638 is coupled tooptics motor 108. Motor interfaces 634, 636, and 638 provide conversions between the digital data and control signaling ofcontrol subsystem 624 and the analog signaling of the motors. In one embodiment, optics motor 80 has fine cogging and provides sufficient torque to rotatereflector 96.Alignment motors -
Level sensor interface 639 is coupled tolevel sensor 80 to receive level indicator signals and pass them to input/output port 651—converting the analog signals oflevel sensor 80 into digital signals.Tilt sensor 600 is coupled to input/output port 653 to indicate whenalignment device 1 has been rotated to provide vertical references. Input/output ports output block 644couple bus 632 touser interfaces output port 652 is coupled tolocal user interface 10. Input/output port 654 is coupled toremote user interface 608.Local user interface 10 provides a portion of the user interface for a user ofalignment device 1 to control the operation ofdevice 1. In different implementations,local user interface 10 may include an alphanumeric keypad or cursor control device, such as a mouse, trackball, stylus, or cursor direction keys. Information provided by the user throughlocal user interface 10 is provided tocontroller 628 through input/output port 652. -
Remote user interface 608 enables a user to communicate withalignment device 1 usingremote control 621—allowing the user to provide instructions.Remote user interface 608 supports the protocol required for facilitating a communications link withremote control 621—providing conversions between the digital signaling ofcontrol subsystem 624 and the signaling ofremote control 621. For example, one type of remote control communicates withremote user interface 608 through a radio frequency connection. Another type of remote control communicates withremote user interface 608 via an infrared signaling connection. - U.S. Pat. No. 5,680,208 and U.S. Pat. No. 5,903,345 provide examples of remote controls and remote control interfaces that can be used with
alignment device 1. U.S. Pat. No. 5,680,208 and U.S. Pat. No. 5,903,345 are hereby incorporated by reference. - In addition to the above-described components,
control subsystem 624 may include a display system and a communications controller. A display system enablesalignment device 1 to display textual and graphical information. The display system may include a cathode ray tube (CRT) display or liquid crystal display (LCD). The display system would receive textual and graphical information fromcontroller 628 through input/output block 644. Potential communications controllers include network interface cards or integrated circuits for interfacingalignment device 1 to a communications network. Instructions for enablingcontrol subsystem 624 to perform processes may be down loaded intomemory 630 over the communications network. - Those skilled in the art will recognize that FIG. 13 only shows one embodiment of
control subsystem 624 and that numerous variations ofcontrol subsystem 624 fall within the scope of the present invention. The components contained incontrol subsystem 624 are those typically found in general purpose computer and control systems, and in fact, these components are intended to represent a broad category of such computer components that are well known in the art. - B. Aligning Horizontal References
- FIG. 14 provides one implementation of a process performed by
alignment device 1 to bringoutput beam 8 into a position parallel to true level. This process is performed whenalignment device 1 is positioned as shown in FIG. 1.Level sensor interface 639 receives a level indication from level sensor 80 (step 700).Control subsystem 624 determines whether the level indication identifiesoutput beam 8 as parallel to true level (step 702). In one embodiment, this determination is made using the current values provided bylevel sensor 80, as described above. Ifoutput beam 8 is level, the process in done. Otherwise,control subsystem 624 determines an appropriate level adjustment to moveoutput beam 8 to the desired position (step 704). In one implementation, this determination is also made using current values fromlevel sensor 80.Control subsystem 624 then issues control signals for one or more ofalignment motors - In one embodiment,
control subsystem 624 directs the operation ofmotors alignment device 1. In one implementation,control subsystem 624 achieves small motor movements by giving a motor a first pulse in a first direction and a larger second pulse in a second direction opposite to the first direction. This results in the motor moving in the second direction. In various embodiments, the second pulse is 4 to 16 times larger than the first pulse, resulting in stepped movements in the second direction of one seventy-fifth of a full motor shaft rotation. - FIG. 15 shows one process for
alignment device 1 to give output beam 8 a desired angular offset from true level.Control subsystem 624 first bringsoutput beam 8 to true level as described above with reference to FIG. 14. Onceoutput beam 8 is level (step 702),control subsystem 624 determines an offset adjustment to make tooptics mounting assembly 24, usingmotors 54 and 74 (step 712).Control subsystem 624 issues control signals formotors - In one embodiment, lead screws46 and 66 have encoders mounted thereon to provide
control subsystem 624 with the position of lead screws 46 and 66.Control subsystem 624 correlates encoder intervals to the angular movement ofoutput beam 8 to determine the magnitude of lead screw rotation required to achieve a desired angular offset (step 712). - In a further embodiment,
level sensor 80 facilitates the operation of a bump sensor. Whenalignment device 1 is jarred,bubble 235 inlevel sensor 80 undergoes a momentary change, such as a rapid change in position.Level sensor 80 sends signals identifying this change to controlsubsystem 624. In response,control subsystem 624 ceases rotation ofreflector 96, reduces or eliminates the power ofoutput beam 8, andlevels alignment device 1 as disclosed above with reference to FIG. 14. - C. Aligning Vertical References
- FIG. 16 shows one embodiment of a process for aligning
output beam 8 whenalignment device 1 is rotated ninety degrees from the position shown in FIG. 1 to produce vertical references. Oncealignment device 1 is rotated,tilt sensor 600 recognizes the rotation ofdevice 1 and issues a signal. In response to the signal,control subsystem 624 sets leadscrews 46 and 66 to a predetermined position (step 800). - In one embodiment,
control subsystem 624 directsmotors Control subsystem 624 detects full extension from a pair of sensors (not shown) that provide signals upon coming into contact withlead screws 46 and 66. After both lead screws are fully extended, control subsystem directsmotors pads screws - Once the lead screws are positioned, a user looks at
bubble level 90 to determine whetheroptics mounting assembly 24 is leveled—the central axis of optics mounting system being parallel to true level (step 802). Ifbubble level 90 signals a level, the process in done (step 804). Otherwise, the user employslocal interface 10 orremote control 621 todirect control subsystem 624 to determine a new level adjustment (step 806). In one embodiment, the user indicates a number of desired lead screw turns, andcontrol subsystem 624 determines the required signal to makemotors Control subsystem 624 then issues the determined signals tomotors 54 and 74 (step 808). The above-described process in then repeated starting withstep 802. In alternate embodiments, the user provides different forms of data to specify lead screw movement, such as the time period a control button is pressed. - FIG. 17 shows a process for
positioning output beam 8 whenalignment device 1 is rotated as described with reference to FIG. 16. This can be useful when a user wants to translate a vertical laser plane fromoutput beam 8 on an incident surface. As a first step, the leveling process described in FIG. 17 is performed. - Once level is detected, an offset adjustment is determined (step810) for achieving a desired yaw. A user employs
local interface 10 orremote control 621 to indicate a magnitude of movement desired fromlead screws 46 and 66. In one embodiment, lead screws 46 and 66 are moved in opposite directions to achieve an output reference translation, while maintaining an orthogonal vertical laser plane or line.Control subsystem 624 converts the user's input into signals that will drivemotors Control subsystem 624 then issues these signals formotors 54 and 74 (step 812). If the resulting output reference position is correct, the process is done (step 814). Otherwise, the process is repeated starting atstep 810. In one embodiment, the user looks atbubble vial 90 and the incident laser beam output to determine if the resulting output beam repositioning is correct. In alternate embodiments, the process shown in FIGS. 16 and 17 are fully automated. - D. Automated Reference Positioning
- In one implementation of
alignment device 1, operators select the location of reference lines and points by providing a location input throughremote control 621 orlocal user interface 10—causing optics motor 108 to rotate penta-prism 96 into a desired position for a reference point or line. In the case of a reference line,motor 108 also dithersshaft 98 between two positions to create a line on an incident surface.Alignment device 1 includes a motor control mechanism that enables operators to accurately position optics motor 108 when selecting reference line and point locations. In one implementation,motor 108 is a direct drive motor, such as the motors used in compact disc players. - FIG. 18 shows a process employed by
alignment device 1 to position optics motor 108.Device 1 controls motor 108 by providing a control signal. The pulse width and frequency of the control signal determine the magnitude of rotation of optics motor 10. Optics motor 108 is first calibrated to identify an ideal pulse width for use in motor 108 (step 960). Next,device 1 determines the motor control signal necessary for positioningmotor 108 to a desired position (step 962) and provides the signal to motor 108 (step 964). One implementation steps for performing the process shown in FIG. 18 us found in U.S. patent application Ser. No. 09/928,244, which is incorporated herein by reference. - The foregoing detailed description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
Claims (3)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/279,754 US20030106226A1 (en) | 2001-12-04 | 2002-10-24 | Alignment device |
AU2002351189A AU2002351189A1 (en) | 2001-12-04 | 2002-12-03 | Alignment device |
PCT/US2002/038409 WO2003048684A1 (en) | 2001-12-04 | 2002-12-03 | Alignment device |
US10/390,523 US20040078989A1 (en) | 2002-10-24 | 2003-03-14 | Reflector mounting in an alignment device |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/004,694 US6625895B2 (en) | 2001-12-04 | 2001-12-04 | Servo-controlled automatic level and plumb tool |
US10/279,754 US20030106226A1 (en) | 2001-12-04 | 2002-10-24 | Alignment device |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/004,694 Continuation-In-Part US6625895B2 (en) | 2001-12-04 | 2001-12-04 | Servo-controlled automatic level and plumb tool |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/390,523 Continuation US20040078989A1 (en) | 2002-10-24 | 2003-03-14 | Reflector mounting in an alignment device |
Publications (1)
Publication Number | Publication Date |
---|---|
US20030106226A1 true US20030106226A1 (en) | 2003-06-12 |
Family
ID=21712053
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/004,694 Expired - Fee Related US6625895B2 (en) | 2001-12-04 | 2001-12-04 | Servo-controlled automatic level and plumb tool |
US10/279,754 Abandoned US20030106226A1 (en) | 2001-12-04 | 2002-10-24 | Alignment device |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/004,694 Expired - Fee Related US6625895B2 (en) | 2001-12-04 | 2001-12-04 | Servo-controlled automatic level and plumb tool |
Country Status (7)
Country | Link |
---|---|
US (2) | US6625895B2 (en) |
EP (1) | EP1463919B1 (en) |
AT (1) | ATE445142T1 (en) |
AU (1) | AU2002353019A1 (en) |
DE (1) | DE60233973D1 (en) |
ES (1) | ES2334496T3 (en) |
WO (1) | WO2003048685A1 (en) |
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- 2002-12-03 AT AT02789985T patent/ATE445142T1/en not_active IP Right Cessation
- 2002-12-03 AU AU2002353019A patent/AU2002353019A1/en not_active Abandoned
- 2002-12-03 DE DE60233973T patent/DE60233973D1/en not_active Expired - Lifetime
- 2002-12-03 EP EP02789985A patent/EP1463919B1/en not_active Expired - Lifetime
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Also Published As
Publication number | Publication date |
---|---|
AU2002353019A1 (en) | 2003-06-17 |
EP1463919B1 (en) | 2009-10-07 |
US6625895B2 (en) | 2003-09-30 |
EP1463919A1 (en) | 2004-10-06 |
ES2334496T3 (en) | 2010-03-11 |
DE60233973D1 (en) | 2009-11-19 |
US20030101605A1 (en) | 2003-06-05 |
WO2003048685A1 (en) | 2003-06-12 |
EP1463919A4 (en) | 2006-09-06 |
ATE445142T1 (en) | 2009-10-15 |
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