Laser-based alignment tool

• US 7,497,018 B2
• Filed: 05/26/2006
• Issued: 03/03/2009
• Est. Priority Date: 05/26/2006
• Status: Expired due to Fees

• Current Assignee: Fluke Corporation (Fortive Corp.)
• Original Assignee: PLS Pacific Laser Systems LLC (Danaher Corporation)
• Inventors: Luo, Yongxin, Baylis, William H., Hersey, William
• Primary Examiner(s): Bennett; G. Bradley
• Assistant Examiner(s): Johnson; Amy Cohen
• Application Number:
  US11/442,003
• Publication Number:
  US 20070271800A1
• Time in Patent Office: 1,012 Days
• Field of Search: 332/27, 332/28, 33281-286, 332/76, 332/77, 33D/IG.21, 356/445, 356/399, 356/400
• US Class Current: 33/286
• CPC Class Codes: G01C 15/004 Reference lines, planes or sectors
• CPC Class Codes: G01C 15/105 Optical plumbing
• 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.

Claims

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

a housing, wherein the housing is dimensioned such that the apparatus can fit within the palm of a human hand;

a projection unit pendulously suspended in the housing to project output beams to indicate level, plumb and square where the projection unit includes a vertical projection module and a horizontal projection module and where each of the vertical and horizontal projection modules include;

a laser emitting diode to emit a laser beam directly incident on a collimator, the collimator comprising a single lens,

the collimator configured to collimate the laser beam into a collimated beam and project the collimated beam on a planar reflective surface;

a planar reflective surface orientated at an angle of approximately 45°

to a path of the collimated beam projected from the collimator and configured to divert the path of the collimated beam approximately 90° and

toward a partial-conical reflective surface;

a conical reflective surface formed from at least approximately 180°

of an exterior surface of a cone and configured to reflect the diverted collimated beam into an approximately 180°

fanned output beam, where the conical reflective surface is positioned relative to the planar reflective surface such that a center of the collimated beam is incident on a front face of the cone and is not incident on the apex of the cone;

where the vertical projection module generates a substantially vertical output beam and the horizontal projection module generates a substantially horizontal output beam, the vertical and horizontal output beams being projected from the housing in different but generally perpendicularly related directions, whereby the output beams can be used to indicate level, plumb and square alignment; and

a damper to dampen pendular motion of the projection unit.

2. The apparatus of claim 1, where:

the vertical projection module and the horizontal projection module are positioned within the apparatus such that the vertical output beam and the horizontal output beam both emanate from a same face of the apparatus.

3. The apparatus of claim 1, where:

each collimator is an aspheric lens and each collimated beam has an elliptically shaped cross-section.

4. The apparatus of claim 1, further comprising:

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

5. The apparatus of claim 1, further comprising:

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

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

6. The apparatus of claim 5, wherein:

the error indicator suspends projection of the vertical and horizontal output beams.

7. The apparatus of claim 5, 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.

8. The apparatus of claim 5, 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.

9. The apparatus of claim 5, where:

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

10. The apparatus of claim 1, where 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.

11. 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 horizontal output beam that can be used to indicate level;

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

in response to a third user input, the projection unit projects simultaneously the horizontal and vertical 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 horizontal and vertical output beams, whereby the output beams can be used to at least indicate square.

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

a housing, wherein the housing is dimensioned such that the apparatus can fit within the palm of a human hand;

a projection unit pendulously suspended in the housing to project output beams to indicate level, plumb and square where the projection unit includes a vertical projection module and a horizontal projection module and where each of the vertical and horizontal projection modules include;

a laser emitting diode to emit a laser beam directly incident on a collimator, the collimator comprising a single lens,

the collimator configured to collimate the laser beam into a collimated beam and project the collimated beam on a planar reflective surface;

a planar reflective surface orientated at an angle of approximately 45°

to a path of the collimated beam projected from the collimator and configured to divert the path of the collimated beam approximately 90° and

toward a partial-conical reflective surface;

a partial-conical reflective surface formed from approximately 180°

of an exterior surface of a cone and configured to reflect the diverted collimated beam into an approximately 180°

fanned output beam;

where the vertical projection module generates a substantially vertical output beam and the horizontal projection module generates a substantially horizontal output beam, the vertical and horizontal output beams being projected from the housing in different but generally perpendicularly related directions, whereby the output beams can be used to indicate level, plumb and square alignment; and

a damper to dampen pendular motion of the projection unit;

where the vertical projection module is mounted relative the housing at an angle γ

relative to a vertical axis of the housing and where the approximately 180°

fanned output beam from the vertical projection module is rotated approximately the angle γ

from a vertical orientation.

13. The apparatus of claim 12, where the angle γ

is approximately 15°

.

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

a housing, wherein the housing is dimensioned such that the apparatus can fit within the palm of a human hand;

a projection unit pendulously suspended in the housing to project output beams to indicate level, plumb and square where the projection unit includes a vertical projection module and a horizontal projection module and where each of the vertical and horizontal projection modules include;

a laser emitting diode to emit a laser beam directly incident on a collimator, the collimator comprising a single lens,

the collimator configured to collimate the laser beam into a collimated beam and project the collimated beam on a planar reflective surface;

a planar reflective surface orientated at an angle of approximately 45°

to a path of the collimated beam projected from the collimator and configured to divert the path of the collimated beam approximately 90° and

toward a partial-conical reflective surface;

a partial-conical reflective surface formed from approximately 180°

of an exterior surface of a cone and configured to reflect the diverted collimated beam into an approximately 180°

fanned output beam;

where the vertical projection module generates a substantially vertical output beam and the horizontal projection module generates a substantially horizontal output beam, the vertical and horizontal output beams being projected from the housing in different but generally perpendicularly related directions, whereby the output beams can be used to indicate level, plumb and square alignment; and

a damper to dampen pendular motion of the projection unit;

where the laser emitting diode included in the vertical projection module is orientated such that the laser beam emitting therefrom has a substantially elliptical cross-section with a long axis of the ellipse orientated at an angle γ

relative to a vertical orientation such that the approximately 180°

fanned output beam is rotated approximately the angle γ

from a vertical orientation.

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

projecting a first laser beam from a first laser diode and a second laser beam from a second laser diode, where the first and second laser beams are projected directly onto a collimator comprising a single lens;

collimating the first laser beam into a first collimated beam and collimating the second laser beam into a second collimated beam, where;

the first collimated beam is incident on a first planar reflective surface and diverted approximately 90°

toward an approximately 180°

first conical reflective surface formed from at least approximately 180°

of an exterior surface of a first cone, where a center of the first collimated beam is incident on a front face of the first conical reflective surface and not an apex of the first cone and the first collimated beam is reflected to form a first output beam fanning approximately 180°

in a first direction; and

the second collimated beam is incident on a second planar reflective surface and diverted approximately 90°

toward an approximately 180°

second conical reflective surface formed from at least approximately 180°

of an exterior surface of a second cone, where a center of the second collimated beam is incident on a front face of the second conical reflective surface and not an apex of the second cone and the second collimated beam is reflected to form a second output beam fanning approximately 180°

in a second direction;

where the first output beam indicates level, the second output beam indicates plumb, and the first and second output beams together indicate square.

16. The method of claim 15, further comprising:

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

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

17. The method of claim 15, wherein the output beams are projected in the image of substantially straight lines.

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

a housing, the housing dimensioned such that the apparatus can fit within the palm of a human hand;

a projection unit pendulously suspended in the housing to project at least one output beam, the projection unit including at least one projection module where the at least one projection module includes;

a laser emitting diode to emit a laser beam directly incident on a collimator comprising a single lens,

the collimator configured to collimate the laser beam into a collimated beam and project the collimated beam on a planar reflective surface;

a planar reflective surface orientated at an angle of approximately 45°

to a path of the collimated beam projected from the collimator and configured to divert the path of the collimated beam approximately 90° and

toward a partial-conical reflective surface;

a conical reflective surface formed from at least approximately 180°

of an exterior surface of a cone and configured to reflect the diverted collimated beam into an approximately 180°

fanned output beam, where the conical reflective surface is positioned relative to the planar reflective surface such that a center of the collimated beam is incident on a front face of the cone and is not incident on the apex of the cone; and

a damper to dampen pendular motion of the projection unit.

19. The apparatus of claim 18, where:

the laser emitting diode emits a laser beam having a substantially elliptical cross-section; and

the collimator is an aspheric lens.

20. A laser projection module comprising:

a laser emitting diode to emit a laser beam directly incident on a collimator comprising a single lens,

the collimator configured to collimate the laser beam into a collimated beam and project the collimated beam on a planar reflective surface;

a planar reflective surface orientated at an angle of approximately 45°

to a path of the collimated beam projected from the collimator and configured to divert the path of the collimated beam approximately 90° and

toward a partial-conical reflective surface; and

a partial-conical reflective surface formed from at least approximately 180°

of an exterior surface of a cone and configured to reflect the diverted collimated beam into an approximately 180°

fanned output beam, where the conical reflective surface is positioned relative to the planar reflective surface such that a center of the collimated beam is incident on a front face of the cone and is not incident on the apex of the cone.

21. The laser projection module of claim 20, where the laser emitting diode emits a laser beam having a substantially elliptical cross-section.

22. The laser projection module of claim 20, where the collimator is an aspheric lens.

23. The laser projection module of claim 20, where the planar reflective surface is a plane mirror.