Laser-based tool for indicating level, plumb and square

• US 6,763,595 B1
• Filed: 06/21/2002
• Issued: 07/20/2004
• Est. Priority Date: 06/21/2002
• Status: Expired due to Term

• Current Assignee: Fluke Corporation (Fortive Corp.)
• Original Assignee: PLS-Pacific Laser Systems (Danaher Corporation)
• Inventors: Hersey, William
• Primary Examiner(s): Fulton, Christopher W.
• Assistant Examiner(s): Hoolahan, Amanda J
• Application Number:
  US10/176,881
• Time in Patent Office: 760 Days
• Field of Search: 332/86, 332/90, 33D/IG.21, 332/91, 332/27, 332/81, 332/83, 332/85, 332/82, 340/686.1, 340/691.4, 340/691.7, 340/691.8
• US Class Current: 33/286
• CPC Class Codes: G01C 15/004 Reference lines, planes or sectors
• CPC Class Codes: G01C 15/12 Instruments for setting out fixed angles, e.g. right angles
• CPC Class Codes: Y10S 33/21 with laser

Abstract

The present invention provides apparatus and a method for projecting an indication of alignment. The invention features forming a first output beam, and a second output beam that is substantially perpendicular to the first output beam. The first output beam indicates level, the second output beam indicates plumb, and the first and second output beams together indicate square. An error indicator indicates an error in the accuracy of the first and second output beams as indicators of level and plumb respectively. The error indicator can be deactivated, such that the first and second output beams together can be used at least to indicate square.

Claims

1. An apparatus for projecting an indication of alignment, comprising:

a housing;

a projection unit pendulously suspended in the housing to project output beams to indicate level, plumb and square,

a damper to dampen pendular motion of the projection unit;

an error indicator to indicate to a user of the apparatus when the housing is inclined such that the accuracy of the level and plumb directions are compromised; and

an override operable by the user to deactivate the error indicator, whereby said output beams can be used at least to indicate square alignment.

2. The apparatus of claim 1, wherein:

the projection unit includes;

at least one laser diode to emit a laser beam,

a first and a second collimator to form a first and a second collimated beam, and

a first and a second optical element to convert the first and second collimated beam into a first and a second linear output beam, the first and second linear output beams being projected from the housing in different but generally perpendicularly related directions, whereby the linear output beams can be used to indicate level, plumb and square alignment.

3. The apparatus of claim 2, wherein:

each collimator includes a focus lens.

4. The apparatus of claim 3, wherein:

each focus lens is an aspheric lens.

5. The apparatus of claim 2, wherein:

each optical element includes a rod lens.

6. The apparatus of claim 2, wherein:

each optical element includes a cylinder lens.

7. The apparatus of claim 2, further comprising:

at least one battery to provide power to at least one laser diode of the projection unit.

8. The apparatus of claim 1, wherein:

the error indicator suspends projection of the output beams.

9. The apparatus of claim 1, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions is compromised, when the housing is inclined in any direction in the range of approximately plus or minus 4 to 9 degrees from horizontal.

10. The apparatus of claim 1, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions is compromised, when the housing is inclined in any direction more than approximately 9 degrees from horizontal.

11. The apparatus of claim 1, wherein:

the override includes digital circuitry to deactivate the error indicator in response to a user input.

12. The apparatus of claim 1, wherein the damper includes:

a magnet mounted in the housing below the projection unit and a damping plate rigidly suspended from the projection unit, such that the damping plate is positioned above the magnet with a gap maintained therebetween sufficiently small that eddy currents are generated in the damping plate by motion thereof above the magnet.

13. The apparatus of claim 1, further comprising:

a user interface configured to receive a user input, wherein;

in response to a first user input, the projection unit projects a first output beam that can be used to indicate level;

in response to a second user input, the projection unit projects a second output beam having a generally perpendicular relationship to the first output beam, whereby the second output beam can be used indicate plumb;

in response to a third user input, the projection unit projects simultaneously the first and second output beams, whereby the output beams can be used to indicate simultaneously level, plumb and square; and

in response to a fourth user input, the override is employed to deactivate the error indicator, and the projection unit simultaneously projects the first and second output beams, whereby the output beams can be used to at least indicate square.

14. An apparatus for projecting an indication of alignment, comprising:

a housing;

a projection unit pendulously suspended in the housing to project linear output beams, the projection unit including;

two laser diodes configured and arranged to emit two laser beams,

two collimators configured and arranged to form the two laser beams into a first and a second collimated beam,

an optical element configured and arranged to convert the first and second collimated beams into a first and a second linear output beam, the first and second linear output beams being projected from the housing in different but generally perpendicularly related directions, whereby said linear output beams can be used to simultaneously indicate level, plumb and square, the optical element including;

a first and second lens to convert the first and second collimated beams into the first and second linear output beams,

a mount to mount the first and second lens to the projection unit, the mount including for each lens;

a member in which a lens can be mounted having openings through which connectors can be positioned, the openings allowing the member to be laterally displaced once the connectors are in position to align the lens such that the output beam is symmetrically projected from the housing,

a base configured to attach to the member by the connectors, where at least one connector includes a longitudinal adjustment mechanism to adjust the position of the lens such that the output beam is substantially straight, the base being mounted onto a support protruding from the projection unit and rotatable about the support to achieve true vertical in relation to the projection unit for the first lens and true horizontal in relation to the projection unit for the second lens; and

a damper configured and arranged to dampen pendular motion of the projection unit.

15. The apparatus of claim 14, further comprising:

an error indicator configured and arranged to indicate when the housing is inclined such that the accuracy of the level and plumb directions are compromised; and

an override device configured and arranged to deactivate the error indicator, whereby the output beams can be used to at least indicate square alignment.

16. The apparatus of claim 15, wherein:

the error indicator suspends projection of the output beams from the projection unit.

17. The apparatus of claim 15, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction in the range of approximately plus or minus 4 to 9 degrees from horizontal.

18. The apparatus of claim 15, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction more than approximately plus or minus 9 degrees from horizontal.

19. The apparatus of claim 14, wherein the longitudinal adjustment mechanism of the mount is a spring.

20. The apparatus of claim 14, wherein:

each collimator includes a focus lens.

21. The apparatus of claim 20, wherein:

each focus lens is an aspheric lens.

22. The apparatus of claim 14, wherein:

the first and second lens are each a rod lens.

23. The apparatus of claim 14, wherein:

the first and second lens are each a cylinder lens.

24. An apparatus for projecting an indication of alignment, comprising:

a housing;

a projection unit pendulously suspended in the housing to project linear output beams, the projection unit including;

two laser diodes configured and arranged to emit two laser beams,

two collimators configured and arranged to form the two laser beams into a first and second collimated beam,

an optical element configured and arranged to convert the first and second collimated beams into a first and a second linear output beam, the first and second linear output beams being projected from the housing in different but generally perpendicularly related directions, whereby said linear output beams can be used to simultaneously indicate level, plumb and square, the optical element including;

a first and second lens to convert the first and second collimated beams into the first and second linear output beams,

a mount to mount the first and second lens to the projection unit, the mount including for each lens;

a member in which a lens can be mounted having openings through which connectors can be positioned, the openings allowing the plate to be laterally displaced once the connectors are in position to align the lens such that the collimated beam is incident on the center of the lens,

a base configured to attach to the member by the connectors, where at least one connector includes a longitudinal adjustment mechanism to adjust the position of the lens so that the lens'"'"' longitudinal axis is substantially perpendicular to the collimated beam, the base being mounted onto a support protruding from the projection unit and rotatable about the support to achieve true vertical in relation to the projection unit for the first lens and true horizontal in relation to the projection unit for the second lens; and

a damper configured and arranged to dampen pendular motion of the projection unit.

25. The apparatus of claim 24, further comprising:

an error indicator configured and arranged to indicate when the housing is inclined such that the accuracy of the level and plumb directions are compromised; and

an override device configured and arranged to deactivate the error indicator, whereby the linear output beams can be used to at least indicate square directions.

26. The apparatus of claim 25, wherein:

the error indicator suspends projection of the linear output beams from the projection unit.

27. The apparatus of claim 25, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction in the range of approximately plus or minus 4 to 9 degrees from horizontal.

28. The apparatus of claim 25, wherein:

the error indicator indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction more than approximately plus or minus 9 degrees from horizontal.

29. The apparatus of claim 24, wherein the longitudinal adjustment mechanism of the mount is a spring.

30. The apparatus of claim 24, wherein:

each collimator includes a focus lens.

31. The apparatus of claim 30, wherein:

each focus lens is an aspheric lens.

32. The apparatus of claim 24, wherein:

the first and second lens are each a rod lens.

33. The apparatus of claim 24, wherein:

the first and second lens are each a cylinder lens.

34. An apparatus for projecting an indication of alignment, comprising:

a housing;

a projection unit pendulously suspended in the housing to project output beams to indicate level, plumb and square directions;

means for damping pendular motion of the projection unit;

error indicator means for indicating to a user of the apparatus when the housing is inclined such that the accuracy of the level and plumb directions are compromised; and

override means operable by the user for deactivating the error indicator means, whereby said output beams can be used at least to indicate square.

35. The apparatus of claim 34, wherein:

the projection unit includes;

laser means for emitting two laser beams,

collimator means for forming the two laser beams into a first and second collimated beam, and

optical means for forming the first and second collimated beams into a first and a second linear output beam, the first and second linear output beams being projected from the housing in different but generally perpendicularly related directions, whereby the linear output beams can be used to indicate level, plumb and square alignment.

36. The apparatus of claim 35, further comprising:

battery means for providing power to the laser means.

37. The apparatus of claim 34, wherein:

the error indicator means suspends projection of the output beams from the projection unit.

38. The apparatus of claim 34, wherein:

the error indicator means indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction in the range of approximately plus or minus 4 to 9 degrees from horizontal.

39. The apparatus of claim 34, wherein:

the error indicator means indicates the housing is inclined such that the accuracy of the level and plumb directions are compromised, when the housing is inclined in any direction more than approximately plus or minus 9 degrees from horizontal.

40. The apparatus of claim 34, wherein:

the override means includes digital circuitry to deactivate the error indicator means in response to a user input.

41. A method for projecting an indication of alignment, the method comprising:

forming a first alignment beam and a second alignment beam that is substantially perpendicular to the first alignment beam, whereby the first alignment beam indicates level, the second alignment beam indicates plumb, and the first and second alignment beams together indicate square;

providing an error indicator to indicate to a user of the first and second alignment beams an error in the accuracy of the first and second alignment beams as indicators of level and plumb respectively; and

deactivating the error indicator to override error indication, such that the first and second alignment beams can be used at least to indicate square alignment.

42. The method of claim 41, further comprising:

projecting a first and second laser beam; and

collimating the first and second laser beam into a first and a second collimated beam incident on a first and a second optical element to convert the first and second collimated beams into the first and second alignment beams.

43. The method of claim 41, wherein the alignment beams are projected in the image of substantially straight lines.

44. A method of projecting an indication of alignment from a laser-based tool, the method comprising:

in response to a first user input received from a user interface that interacts with a user of the laser-based tool;

projecting a first linear output beam that can be used to indicate level, and

indicating to the user any error in the accuracy of the first linear output beam as an indicator of level when the tool is positioned outside of a predetermined accuracy range;

in response to a second user input received from the user interface;

projecting a second linear output beam being substantially perpendicular to the first linear output beam, whereby the second linear output beam can be used to indicate plumb, and

indicating to the user any error in the accuracy of the second linear output beam as an indicator of plumb when the tool is positioned outside of the predetermined accuracy range;

in response to a third user input received from the user interface;

simultaneously projecting the first and the second linear output beams that can be used together to indicate level, plumb and square alignment, and

indicating to the user any error in the accuracy of the first and second linear output beams as indicators of level and plumb when the tool is positioned outside of the predetermined accuracy range; and

in response to a fourth user input received from the user interface;

simultaneously projecting the first and the second linear output beams that together can be used at least to indicate square alignment even when the tool is positioned outside of the predetermined accuracy range and overriding an indication to a user of an error in the accuracy of the first and second linear output beams as indicators of level or plumb when the tool is positioned outside of the predetermined accuracy range.

45. The method of claim 44, wherein the tool is positioned outside the predetermined accuracy range when the tool is inclined in any direction in the range of approximately plus or minus 4 to 9 degrees from horizontal.

46. The method of claim 44, wherein the tool is positioned outside the predetermined accuracy range when the tool is inclined in any direction more than approximately plus or minus 9 degrees from horizontal.