U.S. patent application number 12/824716 was filed with the patent office on 2011-12-29 for two dimension layout and point transfer system.
This patent application is currently assigned to Trimble Navigation Limited. Invention is credited to James N. Hayes, Chris W. Snyder.
Application Number | 20110314684 12/824716 |
Document ID | / |
Family ID | 45115907 |
Filed Date | 2011-12-29 |
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United States Patent
Application |
20110314684 |
Kind Code |
A1 |
Hayes; James N. ; et
al. |
December 29, 2011 |
TWO DIMENSION LAYOUT AND POINT TRANSFER SYSTEM
Abstract
A two-dimension layout system identifies points and their
coordinates, and transfers identified points on a solid surface to
other surfaces in a vertical direction. Two leveling laser light
transmitters are used with a remote unit to control certain
functions. The laser transmitters rotate about the azimuth, and
emit vertical (plumb) laser planes. After being set up using
benchmark points, the projected lines of the laser planes will
intersect on the floor of a jobsite at any point of interest in a
virtual floor plan, under control of a user with the remote unit.
The laser light planes also project lines that will intersect along
the ceiling at a point that is truly plumb above the crossing point
on the floor. The laser planes also provide an "implied" plumb line
that is projected in space, which is visible along a solid vertical
surface between the intersecting floor and ceiling points.
Inventors: |
Hayes; James N.; (Urbana,
OH) ; Snyder; Chris W.; (Union City, OH) |
Assignee: |
Trimble Navigation Limited
|
Family ID: |
45115907 |
Appl. No.: |
12/824716 |
Filed: |
June 28, 2010 |
Current U.S.
Class: |
33/228 ; 33/227;
33/286; 33/291 |
Current CPC
Class: |
G01C 15/004
20130101 |
Class at
Publication: |
33/228 ; 33/291;
33/286; 33/227 |
International
Class: |
G01C 15/00 20060101
G01C015/00; G01C 9/00 20060101 G01C009/00; G01C 15/02 20060101
G01C015/02 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. A layout and point transfer system, comprising: (a) a first
base unit, having a first laser light transmitter that emits a
first laser light plane, and a first processing circuit; and (b) a
second base unit, having a second laser light transmitter that
emits a second laser light plane, and a second processing circuit;
wherein: (c) said system is configured to register locations of
said first and second base units on a physical jobsite surface with
respect to at least two benchmark points that are also located on
said physical jobsite surface; (d) said system is configured to
provide a visual representation of a virtual point on said physical
jobsite surface, by aiming said first laser light plane and said
second laser light plane, to indicate a location of said virtual
point; and (e) a remote unit, having a third processing circuit,
wherein: (i) said remote unit contains a virtual floor plan for use
at said physical jobsite surface; and (ii) said virtual floor plan
includes coordinates for said at least two benchmark points; (f)
said first base unit further comprises: (i) a first self-leveling
device; (ii) a first azimuth position encoder; (iii) a first
azimuth motor drive for automatic positioning said first laser
light transmitter, under control of said remote unit; and (g) said
second base unit further comprises: (i) a second self-leveling
device; (ii) a second azimuth position encoder; (iii) a second
azimuth motor drive for automatic positioning said second laser
light transmitter, under control of said remote unit.
11. The system of claim 10, wherein: (a) said virtual point was
previously registered on said virtual floor plan, relative to said
at least two benchmark points, and said virtual point is selected
as a known point of interest with predetermined coordinates on said
virtual floor plan, and, by use of a first command entered on said
remote unit by a user, said remote unit calculates: (i) a first
azimuth direction for said first laser light transmitter, and (ii)
a second azimuth direction for said second laser light transmitter,
which correspond to said known point of interest; (b) by use of a
second command entered on said remote unit by said user, said
remote unit commands said first laser light transmitter to slew in
the azimuth so that said first laser light plane becomes aimed at
said first azimuth direction; (c) by use of a third command entered
on said remote unit by said user, said remote unit commands said
second laser light transmitter to slew in the azimuth so that said
second laser light plane becomes aimed at said second azimuth
direction; and (d) after both laser light transmitters are properly
aimed, their respective first and second laser light planes now
intersect at said known point of interest and thereby provide a
visual representation at said known point of interest on said
physical jobsite surface.
12. The system of claim 10, wherein: (a) said user selects an
unknown point of interest on said physical jobsite surface; (b) by
manual control of said remote unit by said user, said first laser
light transmitter is slewed in the azimuth until said first laser
light plane passes over said unknown point of interest on said
physical jobsite surface; (c) by manual control of said remote unit
by said user, said second laser light transmitter is slewed in the
azimuth until said second laser light plane passes over said
unknown point of interest on said physical jobsite surface, at
which time said first and second laser light planes provide a pair
of visual lines that intersect at said unknown point of interest on
said physical jobsite surface; and (d) by use of a fourth command
entered on said remote unit by said user: (i) said remote unit
communicates with said first laser light transmitter to determine a
first azimuth angle of said first laser light transmitter based
upon a first signal from said first azimuth position encoder; (ii)
said remote unit communicates with said second laser light
transmitter to determine a second azimuth angle of said second
laser light transmitter based upon a second signal from said second
azimuth position encoder; and (iii) said remote unit performs a
reverse calculation to determine a set of coordinates for said
unknown point of interest that corresponds to a coordinate system
of said virtual floor plan, and thereby enters said unknown point
of interest into said virtual floor plan.
13. (canceled)
14. (canceled)
15. A layout and point transfer system, comprising: (a) a first
base unit, having a first laser light transmitter that emits a
first laser light plane, and a first processing circuit; and (b) a
second base unit, having a second laser light transmitter that
emits a second laser light plane, and a second processing circuit;
wherein: (c) said system is configured to register locations of
said first and second base units on a physical jobsite surface with
respect to at least two benchmark points that are also located on
said physical jobsite surface; and (d) said system is configured to
provide a visual representation of a virtual point on said physical
jobsite surface, by aiming said first laser light plane and said
second laser light plane, to indicate a location of said virtual
point; (e) further comprising a remote unit, having a third
processing circuit, wherein: (i) said remote unit contains a
virtual floor plan for use at said physical jobsite surface; and
(ii) said virtual floor plan includes coordinates for said at least
two benchmark points; and (f) wherein said remote unit further
comprises a display; and an input sensing device that allows a user
to enter commands to said remote unit; (g) wherein said remote unit
is configured: (i) to be in communication with a virtual floor
plan; (ii) to be in communication with said first base unit and
said second base unit; (iii) to depict, on said display, at least
two benchmark points of said virtual floor plan; and (iv) to
depict, on said display, a known virtual point of said virtual
floor plan that is to be plotted on a jobsite physical surface by
said first laser light plane and said second laser light plane.
16. The system of claim 15, wherein said virtual floor plan is in
communication with said remote unit by way of at least one of: (a)
said first base unit includes a transmitter circuit and a receiver
circuit that communicates with a separate computer that contains
said virtual floor plan; and (b) said first base unit includes a
communications port that allows a portable memory device to be
mounted on said port, and said portable memory device contains said
virtual floor plan.
17. The system of claim 15, wherein said remote unit communicates
with said at least two base units, and sends signals to said at
least two base units to command them to aim their laser light
planes at predetermined azimuth angles so that said known virtual
point is visually indicated by intersecting lines on said jobsite
physical surface.
18. (canceled)
19. The base unit of claim 25, wherein said first laser light
transmitter comprises one of: (a) a fan beam laser light emitting
unit; and (b) a rotating laser light beam emitting unit.
20. The base unit of claim 25, wherein said leveling mechanism
comprises one of: (a) a manual leveler unit having a pendulum; (b)
a manual leveler unit having a bubble; and (c) an automatic gravity
sensing leveler unit, that sends signals to a leveling motor
drive.
21. The base unit of claim 18, wherein said null-position
photosensor comprises one of: (a) a split-cell photosensor; (b) a
butt-cell photosensor; (c) a light-conducting rod-style photosensor
having two photocells, one at each end of said light-conducting
rod.
22. The base unit of claim 25, wherein said laser light receiver is
configured: (a) to detect laser light from a second, separate laser
light transmitter; (b) to determine an offset amount between said
first laser light transmitter and said second laser light
transmitter; and (c) to characterize said null-position photosensor
to correct for said offset amount.
23. The base unit of claim 25, further comprising: a transmitter
and a receiver for communicating signals with a remote unit that
allows a user to enter commands to said base unit.
24. The base unit of claim 25, further comprising: an angle encoder
for automatic position sensing in an azimuth direction.
25. A base unit for use in a layout and point transfer system, said
base unit comprising: a first laser light transmitter that emits a
substantially vertical plane of laser light, said first laser light
transmitter being rotatable about a substantially vertical axis; a
laser light receiver having: a null-position photosensor that is
mounted to detect laser light offsets in a substantially horizontal
direction, and an amplifier circuit interfacing between said
null-position photosensor and said laser light receiver; a leveling
mechanism; and an azimuth motor drive for automatic control of an
aiming position of said first laser light transmitter.
26. The base unit of claim 25, further comprising: a second
photosensor with a cylinder lens, for providing gross position
detecting capability.
27. (canceled)
28. (canceled)
29. (canceled)
30. A method for setting up a layout and point transfer system, and
for indicating a known point of interest, said method comprising:
(a) providing a first base unit which includes a first laser light
transmitter that emits a first laser light plane; (b) providing a
second base unit which includes a second laser light transmitter
that emits a second laser light plane; (c) positioning said first
base unit and said second base unit at two different locations on a
solid surface of a jobsite; (d) determining an alignment axis
between said first base unit and said second base unit; (e) aiming
said first laser light transmitter and said second laser light
transmitter so that a first benchmark point is indicated by
intersecting laser light lines along said solid surface, which are
produced by said first and second laser light planes; and
determining a first set of azimuth angles of said first and second
laser light transmitters; (f) aiming said first laser light
transmitter and said second laser light transmitter so that a
second benchmark point is indicated by intersecting laser light
lines along said solid surface, which are produced by said first
and second laser light planes; and determining a second set of
azimuth angles of said first and second laser light transmitters;
(g) by use of said first and second sets of azimuth angles,
determining positions of said first and second base units with
respect to said first and second benchmark points; (h) providing a
virtual jobsite floor plan in at least two dimensions; (i)
providing a remote unit that includes a memory circuit, a display,
and an input sensing device that allows a user to enter commands to
said remote unit, said remote unit being in communication with said
virtual jobsite floor plan; (j) positioning said first base unit
and said second base unit at two different locations on a physical
jobsite surface, and determining an alignment axis therebetween;
(k) determining coordinates for two benchmark points of said
virtual jobsite floor plan, and determining azimuth angles of said
first and second laser light transmitters for each of said two
benchmark points, thereby registering positions of said first and
second base units on said virtual jobsite floor plan; (l) selecting
first coordinates for a first point of interest that was previously
registered in said virtual jobsite floor plan, and slewing said
first and second laser light transmitters in an azimuth direction
to aim at said first coordinates; and (m) visually determining said
first point of interest, by indicating a location at which said
first substantially vertical laser light plane and said second
substantially vertical laser light plane produce intersecting laser
light lines on said physical jobsite surface.
31. The method of claim 30, wherein said step of providing a
virtual jobsite floor plan comprises at least one of: (a) storing a
computer file in said memory circuit of said remote unit; (b)
storing a computer file in a portable memory device and mounting
said portable memory device onto an input/output port of said
remote unit; and (c) storing a computer file in a separate computer
that is in communication with said remote unit by use of a
communications circuit that exchanges data between said remote unit
and said separate computer.
32. The method of claim 30, wherein said step of slewing said first
and second laser light transmitters in an azimuth direction to aim
at said first coordinates occurs by one of: (a) a manual aiming
procedure, by using azimuth angle scales on said first and second
base units to aim said first and second laser transmitters; and (b)
an automatic aiming procedure, by using azimuth motor drives and
azimuth encoders on said first and second base units to aim said
first and second laser transmitters.
33. The method of claim 30, further comprising a step of:
transferring said first point of interest to a ceiling surface by
finding a second location at which said first substantially
vertical laser light plane and said second substantially vertical
laser light plane produce second intersecting laser light lines on
said ceiling surface, in which said second location is
substantially vertically above said first point of interest, with
respect to gravity.
34. The method of claim 33, further comprising a step of: creating
an implied plumb line with respect to gravity, wherein: (a) said
implied plumb line exists between said first point of interest and
said second location, and (b) if a substantially vertical solid
surface is positioned proximal to said first point of interest on
said physical jobsite surface, then said implied plumb line is
visible along the substantially vertical solid surface.
35. The method of claim 30, further comprising a step of: creating
an implied plumb line with respect to gravity, wherein: (a) said
implied plumb line exists above said first point of interest, and
(b) if a substantially vertical solid surface is positioned
proximal to said first point of interest on said physical jobsite
surface, then said implied plumb line is visible along the
substantially vertical solid surface.
36. A method for setting up a layout and point transfer system, for
entering an unknown point of interest into a virtual floor plan,
said method comprising: (a) providing a first base unit which
includes a first laser light transmitter that emits a first laser
light plane; (b) providing a second base unit which includes a
second laser light transmitter that emits a second laser light
plane; (c) positioning said first base unit and said second base
unit at two different locations on a solid surface of a jobsite;
(d) determining an alignment axis between said first base unit and
said second base unit; (e) aiming said first laser light
transmitter and said second laser light transmitter so that a first
benchmark point is indicated by intersecting laser light lines
along said solid surface, which are produced by said first and
second laser light planes; and determining a first set of azimuth
angles of said first and second laser light transmitters; (f)
aiming said first laser light transmitter and said second laser
light transmitter so that a second benchmark point is indicated by
intersecting laser light lines along said solid surface, which are
produced by said first and second laser light planes; and
determining a second set of azimuth angles of said first and second
laser light transmitters; (g) by use of said first and second sets
of azimuth angles, determining positions of said first and second
base units with respect to said first and second benchmark points;
(h) providing a virtual jobsite floor plan in at least two
dimensions; (i) providing a remote unit that includes a memory
circuit, a display, and an input sensing device that allows a user
to enter commands to said remote unit, said remote unit being in
communication with said virtual jobsite floor plan; (j) positioning
said first base unit and said second base unit at two different
locations on a physical jobsite surface, and determining an
alignment axis therebetween; (k) determining coordinates for two
benchmark points of said virtual jobsite floor plan, and
determining azimuth angles of said first and second laser light
transmitters for each of said two benchmark points, thereby
registering positions of said first and second base units on said
virtual jobsite floor plan; (l) selecting an unknown physical point
of interest on said physical jobsite surface, and slewing said
first and second laser light transmitters in an azimuth direction
to aim at said unknown physical point of interest until said first
substantially vertical laser light plane and said second
substantially vertical laser light plane produce intersecting laser
light lines on said physical jobsite surface at said unknown
physical point of interest; (m) entering azimuth aiming angles of
said first and second laser light transmitters into said remote
unit, thereby determining angular coordinates of said unknown
physical point of interest with respect to said first and second
base units; and (n) using reverse calculations, plotting said
unknown physical point of interest into said virtual jobsite floor
plan, thereby registering said unknown physical point of
interest.
37. The method of claim 36, wherein said step of providing a
virtual jobsite floor plan comprises at least one of: (a) storing a
computer file in said memory circuit of said remote unit; (b)
storing a computer file in a portable memory device and mounting
said portable memory device onto an input/output port of said
remote unit; and (c) storing a computer file in a separate computer
that is in communication with said remote unit by use of a
communications circuit that exchanges data between said remote unit
and said separate computer.
38. The method of claim 36, wherein said step of slewing said first
and second laser light transmitters in an azimuth direction to aim
at said unknown physical point of interest occurs by one of: (a)
manually adjusting azimuth directions that said first and second
laser transmitters are emitting said first and second substantially
vertical laser light planes until said first substantially vertical
laser light plane and said second substantially vertical laser
light plane produce intersecting laser light lines on said physical
jobsite surface at said unknown physical point of interest, in that
said user visually determines when said intersecting laser light
lines are correctly positioned; and (b) entering commands at said
remote unit, causing azimuth drive motors mounted in said first and
second base units to adjust azimuth directions that said first and
second laser transmitters are emitting said first and second
substantially vertical laser light planes until said first
substantially vertical laser light plane and said second
substantially vertical laser light plane produce intersecting laser
light lines on said physical jobsite surface at said unknown
physical point of interest, in that said user visually determines
when said intersecting laser light lines are correctly
positioned.
39. The method of claim 36, further comprising a step of: before
entering said azimuth aiming angles of said first and second laser
light transmitters into said remote unit, determining said azimuth
aiming angles of said first and second laser light transmitters by
one of: (a) manually taking visual readings, using azimuth angle
scales on said first and second base units; and (b) automatically
taking azimuth position readings, using azimuth encoders on said
first and second base units.
Description
TECHNICAL FIELD
[0001] The technology disclosed herein relates generally to layout
"surveying" equipment and is particularly directed to a
two-dimension layout system of the type which identifies points and
their coordinates, and transfers identified points on a surface to
other surfaces in a vertical direction. Embodiments are
specifically disclosed using two laser light transmitters with a
remote unit to control certain functions. The laser transmitters
may be identical. Preferably the laser transmitters include a
self-leveling capability, and exhibit a rotation about the azimuth,
and a vertical (plumb) laser plane (or rotating line) output. When
the system is set up it is capable of aiming (by rotation) each of
the vertical (laser light) plane outputs from the transmitters
(which are positioned at some distance apart), so that the
projected lines (of the laser light planes) will cross on the
surface at any given desired point on the jobsite. In addition, the
extent (divergence) of the projected laser light planes are such
that they also cross overhead on the ceiling, which crossing point
occurs at a location that is truly plumb above the corresponding
crossing point on the surface. A further feature of the system
provides an "implied" plumb line that is projected in space, and is
represented by the intersection of the two planes between the point
intersections on the surface and the ceiling. This implied plumb
line is visible if a solid surface (or perhaps smoke) is placed in
the volumetric space where the plumb line is projected. The system
includes a methodology for simplified layout and direct point
transfer to the ceiling.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
BACKGROUND
[0003] The present invention relates generally to a laser system
that provides the elements for visually locating points of interest
on a two-dimensional horizontal surface for use in primarily
interior construction environments. A simple, accurate and cost
effective system for the layout of floor plans at the jobsite has
long been in need. Conventional GPS is not usable inside standard
steel construction buildings. Previous laser based systems have
been overly complex and expensive, missing the mark in almost every
area required for this market.
[0004] In prior art laser based positioning systems, such as
disclosed in U.S. Pat. No. 5,100,229, three or more laser
transmitters (beacons) are placed around the perimeter of a work
site. Each transmitter emits a plane of light approximately 45
degrees to vertical while continuously rotating at a constant
speed. The beams from each transmitter must each have their own
unique and highly controlled speed of rotation, or alternatively
their own unique modulation frequency, so they may be distinguished
from each other. A strobe on each provides a reference signal to
start a series of timing events that are ultimately utilized to
triangulate position. The system can be used for two-dimensional or
three-dimensional applications. The complexity of this method is
very high, and the requirement of having constant rotational laser
scanning is critical. In addition, it is computationally intensive,
especially when setting up the system.
[0005] Another prior apparatus, such as disclosed in U.S. Pat. No.
5,076,690, uses a rotating laser beam to scan retro-reflective bar
coded targets placed around the perimeter of the job site. The
portable transmitter/receiver utilizes optical collection optics to
receive the retro-reflected energy from at least three of the
targets. A rotational encoder assumes a relatively constant
rotation speed and interpolates between each perimeter slot of the
encoder disk a precision azimuth angle for each acquired target.
After a set-up procedure that uses at least two known benchmarks,
the working field is `scaled` so that any other point of interest
can be found with a two-dimensional working plane. A complex method
to precision calibrate and characterize each leading edge of each
rotary encoder slot is required to provide the level of precision
sought in the construction layout application. Job site
obstructions also become a challenge when acquiring sufficient
targets in the right place, with respect to the position of the
transmitter, to provide a strong calculation of position.
[0006] Still another method of laser based positioning is disclosed
in U.S. Pat. No. 7,110,092. Two parallel laser beams are emitted at
a known distance from each other. The beams are rotated together at
a constant speed, thus defining the working plane. A laser receiver
is used to determine when each beam becomes incident on the sensing
element. Because the rotation of the beams is assumed to be
constant, the timing of the two beams incident on the receiver
becomes faster at greater distances and thus is a smaller
percentage of the time it takes to traverse the entire perimeter.
Distance is extrapolated from this information. Further, if an
index is provided to indicate the start of rotation of the laser
beams, then position can be found. Constant rotation speed is again
very critical, and the position calculation for this method
typically has not been sufficient accuracy for what is required for
typical construction jobsite layout.
[0007] Still other laser based methods have been used to provide
the construction layout function. Several of them, such as those
manufactured and marketed by SL Laser and Flexijet, utilize a
pointing laser beam that is mounted on a rotating base that can
provide azimuth angle and a frame with a rotatable sextant that can
provide altitude angle. In this manner a laser beam can be pointed
in the direction of a desired point of interest and projected onto
a surface. The indicated point location is accurate only if the
surface onto which it is projected is both flat and at the
theoretically expected elevation. Otherwise serious errors can
occur, and become increasingly large as the incident projection
angle onto the surface becomes steeper.
[0008] It is seen that there remains a need for a more effective
positioning system for use in the construction industry and, more
specifically, for floor layout indoors. This need encompasses the
desire for more simplicity so that its concept of operation and
method of use is much more intuitive to the user. Set up of the
system should be straightforward and fast. In addition, there is a
need to provide a visual system for interior use. Doing so will add
to the intuitive nature of the system as well as reduce the overall
expense of the system, because the function of automatically
detecting an encoded or modulated laser signal is not required.
Lastly, there is a need to provide a system where the projection
onto a surface is not subject to flatness errors of the incident
surface.
SUMMARY
[0009] Accordingly, it is an advantage to provide a floor layout
system that includes two base units that can have an alignment axis
established therebetween, and a remote unit that communicates with
both of the base units, in which the system is configured to
provide a visual presentation of virtual points on a jobsite
physical surface that have predetermined coordinates, relative to
locations of at least two benchmark points.
[0010] It is another advantage to provide a base unit that has a
laser transmitter having an optical emission that creates a
vertical laser light plane, a laser receiver with a null
position-detecting capability, in which the receiver is mounted to
detect laser light offsets in the horizontal direction, and a
leveling mechanism.
[0011] It is yet another advantage to provide a remote unit that
has a computer processing circuit and a memory circuit, along with
a communication circuit that can communicate to at least one base
unit of a floor layout system, in which the remote unit also has a
display and a user controlled input device; the remote unit also is
in communication with a virtual building plan, and its display is
capable of depicting at least two benchmark points and at least one
known virtual point that is to be visually indicated on a jobsite
physical surface.
[0012] It is still another advantage to provide a method for
setting up a floor layout system, in which the system includes two
base units each having a laser transmitter, wherein a user will
perform certain functions on a jobsite, including: (a) positioning
the two base units on a jobsite floor, (b) aligning the two laser
transmitters of both base units to create an alignment axis, (c)
locating two benchmark points with intersecting laser light from
the two laser transmitters, and (d) determining azimuth angles of
the two laser transmitters for those benchmark points.
[0013] It is a further advantage to provide a method for using a
floor layout system having "known" points of a building plan, in
which the system includes two base units each with a laser
transmitter, and including a remote unit that is communication with
the base units; wherein a user performs certain functions,
including: (a) positioning the two laser transmitters of the base
units on a jobsite floor to establish an alignment axis
therebetween, (b) providing a virtual jobsite floor plan, (c)
determining coordinates of two benchmark points of the virtual
floor plan and determining azimuth angles of the two laser
transmitters corresponding to those benchmark points, (d) entering
coordinates for a point of interest on the virtual floor plan, and
slewing the two laser transmitters to those coordinates, and (e)
visually indicating the physical point of interest on the jobsite
floor, by use the laser light lines produced by the laser
transmitters.
[0014] It is yet a further advantage to provide a method for using
a floor layout system to enter "unknown" points of a jobsite into a
virtual floor plan, in which a system has two base units each with
a laser transmitter, and a remote unit that is in communication
with the base units; wherein a user performs certain functions,
including: (a) positioning the two laser transmitters of the base
units on a jobsite floor to establish an alignment axis
therebetween, (b) providing a virtual jobsite floor plan, (c)
determining coordinates of two benchmark points of the virtual
floor plan and determining azimuth angles of the two laser
transmitters corresponding to those benchmark points, (d) selecting
an "unknown" physical point of interest on the jobsite floor, (e)
slewing the two laser transmitters so that they create visible
intersecting light lines at that physical point of interest, (f)
entering the azimuth angles for the two laser transmitters to
determine the corresponding coordinates of that point of interest
on the remote unit, and (g) using reverse calculations, plotting
that physical point of interest on the virtual floor plan of the
remote unit.
[0015] Additional advantages and other novel features will be set
forth in part in the description that follows and in part will
become apparent to those skilled in the art upon examination of the
following or may be learned with the practice of the technology
disclosed herein.
[0016] To achieve the foregoing and other advantages, and in
accordance with one aspect, a layout and point transfer system is
provided, which comprises: (a) a first base unit, having a first
laser light transmitter that emits a first laser light plane, and a
first processing circuit; and (b) a second base unit, having a
second laser light transmitter that emits a second laser light
plane, and a second processing circuit; wherein: (c) the system is
configured to register locations of the first and second base units
on a physical jobsite surface with respect to at least two
benchmark points that are also located on the physical jobsite
surface; and (d) the system is configured to provide a visual
representation of a virtual point on the physical jobsite surface,
by aiming first laser light plane and the second laser light plane,
to indicate a location of the virtual point.
[0017] In accordance with another aspect, a base unit for use in a
floor layout and point transfer system is provided, which
comprises: a first laser light transmitter that emits a
substantially vertical plane of laser light, the first laser light
transmitter being rotatable about a substantially vertical axis; a
laser light receiver having: a null-position photosensor that is
mounted to detect laser light offsets in a substantially horizontal
direction, and an amplifier circuit interfacing between the
null-position photosensor and the laser light receiver; and a
leveling mechanism.
[0018] In accordance with yet another aspect a method for setting
up a layout and point transfer system is provided, in which the
method comprises the following steps: (a) providing a first base
unit which includes a first laser light transmitter that emits a
first laser light plane; (b) providing a second base unit which
includes a second laser light transmitter that emits a second laser
light plane; (c) positioning the first base unit and the second
base unit at two different locations on a solid surface of a
jobsite; (d) determining an alignment axis between the first base
unit and the second base unit; (e) aiming the first laser light
transmitter and the second laser light transmitter so that a first
benchmark point is indicated by intersecting laser light lines
along the solid surface, which are produced by the first and second
laser light planes; and determining a first set of azimuth angles
of the first and second laser light transmitters; (f) aiming the
first laser light transmitter and the second laser light
transmitter so that a second benchmark point is indicated by
intersecting laser light lines along the solid surface, which are
produced by the first and second laser light planes; and
determining a second set of azimuth angles of the first and second
laser light transmitters; and (g) by use of the first and second
sets of azimuth angles, determining positions of the first and
second base units with respect to the first and second benchmark
points.
[0019] Still other advantages will become apparent to those skilled
in this art from the following description and drawings wherein
there is described and shown a preferred embodiment in one of the
best modes contemplated for carrying out the technology. As will be
realized, the technology disclosed herein is capable of other
different embodiments, and its several details are capable of
modification in various, obvious aspects all without departing from
its principles. Accordingly, the drawings and descriptions will be
regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings incorporated in and forming a part
of the specification illustrate several aspects of the technology
disclosed herein, and together with the description and claims
serve to explain the principles of the technology. In the
drawings:
[0021] FIG. 1 is a block diagram of the major components of a
layout and point transfer system, as constructed according the
principles of the technology disclosed herein.
[0022] FIG. 2 is a block diagram of the major components of a laser
transmitter that is part of a base unit depicted in FIG. 1.
[0023] FIG. 3 is a block diagram of the major components of a laser
receiver that is part of a base unit that is depicted in FIG.
1.
[0024] FIG. 4 is a block diagram of the major components of a
remote unit that is part of the system of FIG. 1.
[0025] FIG. 5 is a flow chart of the steps performed by a system
set-up routine, for the system depicted in FIG. 1.
[0026] FIG. 6 is a flow chart of the steps performed by a routine
to find a "known" point on a floor layout plan, using the system of
FIG. 1.
[0027] FIG. 7 is a flow chart of the steps performed by a routine
to enter an "unknown" point on a jobsite, using the system of FIG.
1.
[0028] FIG. 8 is a diagrammatic view of an "automatic" base unit,
as used in the system of FIG. 1.
[0029] FIGS. 9-13 are diagrammatic views of how a human user would
use the system of FIG. 1, first to align a pair of transmitter
axes, then to align the transmitters to two different benchmark
points, then to align the laser planes to a floor point, and
finally to align the laser planes along a plumb line of a wall
surface.
[0030] FIGS. 14-19 are diagrammatic views showing how two base
units of the system of FIG. 1 can automatically establish an
alignment axis therebetween.
[0031] FIG. 20 is an elevational view of a conventional laser
position pointing system that is known in the prior art, depicting
its attempt to project a position of a point of interest on an
uneven jobsite floor.
[0032] FIG. 21 is an elevational view of the system of FIG. 1,
showing two base units with laser transmitters that correctly
project a position of a point of interest on an uneven jobsite
floor.
[0033] FIG. 22 is a diagram showing positions of physical points
and angles involved in a set-up routine.
[0034] FIG. 23 is a diagram showing positions of physical points
and angles involved in a routine for locating a known point of
interest.
[0035] FIG. 24 is a diagram showing positions of physical points
and angles involved in a routine for entering an unknown point of
interest.
DETAILED DESCRIPTION
[0036] Reference will now be made in detail to the present
preferred embodiment, an example of which is illustrated in the
accompanying drawings, wherein like numerals indicate the same
elements throughout the views.
[0037] It is to be understood that the technology disclosed herein
is not limited in its application to the details of construction
and the arrangement of components set forth in the following
description or illustrated in the drawings. The technology
disclosed herein is capable of other embodiments and of being
practiced or of being carried out in various ways. Also, it is to
be understood that the phraseology and terminology used herein is
for the purpose of description and should not be regarded as
limiting. The use of "including," "comprising," or "having" and
variations thereof herein is meant to encompass the items listed
thereafter and equivalents thereof as well as additional items.
Unless limited otherwise, the terms "connected," "coupled," and
"mounted," and variations thereof herein are used broadly and
encompass direct and indirect connections, couplings, and
mountings. In addition, the terms "connected" and "coupled" and
variations thereof are not restricted to physical or mechanical
connections or couplings.
[0038] In addition, it should be understood that embodiments
disclosed herein include both hardware and electronic components or
modules that, for purposes of discussion, may be illustrated and
described as if the majority of the components were implemented
solely in hardware.
[0039] However, one of ordinary skill in the art, and based on a
reading of this detailed description, would recognize that, in at
least one embodiment, the electronic based aspects of the
technology disclosed herein may be implemented in software. As
such, it should be noted that a plurality of hardware and
software-based devices, as well as a plurality of different
structural components may be utilized to implement the technology
disclosed herein.
[0040] It will be understood that the term "circuit" as used herein
can represent an actual electronic circuit, such as an integrated
circuit chip (or a portion thereof), or it can represent a function
that is performed by a processing device, such as a microprocessor
or an ASIC that includes a logic state machine or another form of
processing element (including a sequential processing device). A
specific type of circuit could be an analog circuit or a digital
circuit of some type, although such a circuit possibly could be
implemented in software by a logic state machine or a sequential
processor. In other words, if a processing circuit is used to
perform a desired function used in the technology disclosed herein
(such as a demodulation function), then there might not be a
specific "circuit" that could be called a "demodulation circuit;"
however, there would be a demodulation "function" that is performed
by the software. All of these possibilities are contemplated by the
inventors, and are within the principles of the technology when
discussing a "circuit."
[0041] System Set-Up; Introduction
[0042] It is assumed that there exists at least two known points
(also sometimes referred to as "benchmarks" herein) on the jobsite
which can be utilized for the setting up the system. These
benchmark points would have been established from previous survey
efforts. FIGS. 9-11 illustrate a basic example of how the system
can be set up. A first step (see FIG. 9) illustrates an alignment
of the transmitters' output vertical planes to each other with the
use of an RF (radio frequency) remote unit. This establishes an
axis between the centerlines of each transmitter "base unit" device
and indexes the angular encoders to that. This process can be
performed by visually aligning the transmitter planes to each
other, but may be facilitated with the addition of a split
photocell on the transmitter base units that would guide and lock
into place the respective planes, adding convenience and precision
to the process.
[0043] A second step (see FIG. 10) illustrates the establishment of
the first known benchmark. The vertical planes from each
transmitter base unit are commanded to position over the point of
interest by the handheld radio remote unit, and then their
coordinates are entered. The second known benchmark is entered in a
similar manner, in a third step (as illustrated in FIG. 11). After
this third step, the remote unit's computer system has sufficient
set-up information to calculate the location and "find" any other
point of interest within the working area. The above example steps
will be discussed below, in greater detail.
[0044] Finding a "Known" Point; Introduction
[0045] FIG. 12 illustrates a basic configuration of laser
transmitters and output laser plane configurations for a system
that was previously set-up. The vertical laser light planes emitted
by the base unit laser transmitters can be visible red laser light;
however, other light wavelengths could be used instead, such as
infrared, green, or other light wavelengths as well. For many of
the applications using this system, it will be preferable for the
laser light to be of a visible wavelength, and the description
hereinbelow will assume that is the case.
[0046] The laser planes emanate from the two laser transmitters'
rotors, which have capability of rotation about the vertical
instrument axis. This allows each laser transmitter the ability to
position its visible vertical plane at any angle about its rotation
axis, and then to hold static at that position. The laser
transmitters are located at a distance (not necessarily known) from
each other; in this example, they are positioned near each corner
of the room. As can be seen from FIG. 12, a first point is formed
on the floor at the intersection of the two laser planes. In
addition, a second point is formed on the ceiling, above the first
point on the floor. If the two laser planes are truly vertical with
respect to gravity, then the point on the ceiling is in a location
that is plumbed over the point on the floor. Another interesting
aspect is the formation of an implied plumb line where the two
laser planes intersect.
[0047] When the system is set up on a jobsite, the laser planes can
be commanded to rotate into position so that the intersection
identifies any point of interest (on the floor or ceiling) that the
user chooses. This is accomplished via the remote unit (using, for
example, a radio link or an IR link) that communicates with the two
base unit laser transmitters, thereby allowing the user mobility
throughout the room and enabling him/her to be at the physical
location where the layout work is being performed.
[0048] Once the set-up is completed the user may enter coordinates
of interest into the handheld remote unit. When this occurs each
vertical laser plane can be commanded to slew into position so that
the visible intersection will reveal the physical location. Points
of interest may also be downloaded from other support software so
that the user can simply choose various points of interest from a
listing. Floor layout can proceed accordingly. Because there exists
a "second" intersection on the ceiling that is continuously plumbed
over the "first" intersection on the floor, point transfer from
floor to ceiling can proceed simultaneously. This is of use in
laying out sprinkler systems and the like. In addition, there is a
vertical implied plumb line at the intersection of the two vertical
planes (i.e., between the two floor and ceiling intersection
points). This vertical implied plumb line can be used to help align
and set studded walls--an example of this methodology is
illustrated in FIG. 13. These examples will be discussed below, in
greater detail.
[0049] Details of System Hardware
[0050] Referring now to FIG. 1, an entire layout and point transfer
system, generally designated by the reference numeral 10, is
depicted in block diagram form. A first base unit is generally
designated by the reference numeral 20, and is also referred to on
FIG. 1 as "BASE UNIT #A." A second base unit is generally
designated by the reference numeral 30, and is also referred to on
FIG. 1 as "BASE UNIT #B."
[0051] Base unit 20 includes a laser transmitter "T1," at reference
numeral 22. Laser transmitter 22 includes a processing circuit, a
memory circuit, an input/output circuit, a laser light source, and
a leveling platform.
[0052] Base unit 20 contains a laser receiver "R1," in a preferred
mode of this system. This laser receiver is also designated by the
reference numeral 24, and includes a processing circuit, a memory
circuit, an input/output circuit, and at least one photosensor.
Different configurations of photosensors can be used for this laser
receiver, as discussed below in greater detail.
[0053] Base unit 20 further includes an aiming platform "A1," which
is designated by the reference numeral 26. This aiming platform
includes an angle encoder, and an angle drive circuit. This aiming
platform 26 will be described in greater detail below.
[0054] Base unit 30 includes a laser transmitter, in this instance
referred to as "T2," and designated by the reference numeral 32.
Laser transmitter 32 also includes a processing circuit, memory
circuit, input/output circuit, laser light source, and a leveling
platform.
[0055] Base unit 30 also includes a laser receiver referred to as
"R2," and generally designated by the reference numeral 34. This
laser receiver also includes a processing circuit, memory circuit,
input/out circuit, and photosensors.
[0056] Base unit 30 also includes an aiming platform, referred to
as "A2," and generally designated by the reference numeral 36. This
second aiming platform includes an angle encoder, and an angle
drive circuit. These are similar to the same types of devices in
the aiming platform 26, and will be discussed below in greater
detail.
[0057] The system 10 also includes a remote unit, which is
generally designated by the reference numeral 40 on FIG. 1. Remote
unit 40 includes a processing circuit, a memory circuit, an
input/out circuit, a display, and a keypad. Alternatively, remote
unit 40 could include a touch screen display which would
incorporate the main functions of a keypad, without having a
separate keypad on the unit. The memory circuit of remote unit 40
can have two components: a first internal component, and either an
external component or a "bulk memory" component, which is
designated by the reference numeral 42 on FIG. 1. The external
characteristic of memory circuit 42 could be comprised of a flash
memory or other type of portable memory device, such as a "stick
ROM." Such a portable memory device could be carried by a user, and
could be plugged into a port of the remote unit 40, if desired.
This will be discussed in greater detail below.
[0058] Another possible component of system 10 is a computer
generally designated by the reference numeral 50. This computer is
referred to as an "ARCHITECT COMPUTER," on FIG. 1. Although the
owner of computer 50 may or may not truly be an architect, for the
purposes of this description, it will be assumed that computer 50
includes floor plans or some other type of computer files that were
either created or used by an architect, or by some type of building
engineer. This assumes that the system 10 is going to be used on a
jobsite in which a building will be constructed. Of course, other
types of structures or perhaps highways can use the technology
disclosed herein, and such a jobsite may not have any type of
enclosed building structure at all.
[0059] The computer 50 includes a processing circuit, a memory
circuit, and an input/output circuit. The memory circuit of
computer 50 will either contain floor plans (designated at 54), or
some other type of computer files such as computer-aided drafting
(CAD) files at 52, on FIG. 1. It should be noted that the remote
unit 40 itself could have some type of computer-aided architecture
or CAD software installed thereon (depending on how "powerful" the
computer/memory system is for the remote unit), and in that event,
the virtual floor plan could also be directly contained in memory
circuit 42, and displayed in two, or perhaps even three
dimensions.
[0060] It will be understood that all of the main units illustrated
on FIG. 1 include some type of input/output circuit, and these
types of circuits include communications circuits. Such
communication circuits possibly could be plug-in ports, such as USB
ports; moreover, such input/output circuits also can include
wireless communications circuits, such as low power radio-frequency
transmitters and receivers, or other types of wireless
communications ports that use other wavelengths, such as infrared
light, for transmitting and receiving data between the various
units. This type of technology is already available today, although
certainly there will be newer forms invented in the future, that
can still be used in the system 10 of FIG. 1.
[0061] Referring now to FIG. 2, a block diagram of a laser
transmitter used in one of the base units is illustrated, and is
generally designated by the reference numeral 100. Laser
transmitter 100 includes a processing circuit 110, which will have
associated random access memory (RAM) at 112, associated read only
memory (ROM) at 114, and at least one input/output circuit at 116.
These devices 112, 114, and 116 communicate with the processing
circuit 110 by use of a bus 118, which typically is referred to as
an address bus or a data bus, and can also contain other types of
signals, such as interrupts and perhaps other types of timing
signals.
[0062] The input/output circuit 116 will sometimes also be referred
to herein as an I/O circuit. This I/O circuit 116 is a primary
interface between the real world devices and the processing circuit
110. It is in communication with various communications devices and
also various types of motor drive circuits and sensor circuits.
[0063] The input/output circuit 116 is in communication with a
communications port A, which is generally designated by the
reference numeral 120. Communications port 120 includes a
transmitter circuit 122 and receiver circuit 124. Communications
port 120 is provided to exchange data information with the remote
unit 40, which on FIG. 2 is referred to as the remote unit 300. The
communication link between remote unit 300 and communications port
120 is designated by the reference numeral 126. In a preferred mode
of this system, the communication link 126 will be wireless,
although certainly a cable could be connected between the
communications port 120 and the remote unit 300, if desired.
[0064] A second communications port, referred to as port B is
generally designated to by the reference numeral 130 on FIG. 2.
This port 130 comprises a data interface with an input circuit at
132 and output circuit at 134. Communications port 130 transfers
data to and from a null-position photosensor, generally designated
by the reference numeral 200, using a communication path 136. While
it would be possible for communication link 136 to be wireless,
there is no particular need for that to be so. The null-position
photosensor 200 will typically be mounted directly on the base
unit, as will be the laser transmitter 100. Therefore, a direct
"wired" link will be typical.
[0065] Laser transmitter 100 also includes a leveling motor drive
circuit, generally designated by the reference numeral 140. This
drive circuit provides the voltage and current for a leveling motor
142. In addition, it receives signals from a level sensor 144, and
these input signals will determine what types of commands will be
sent to the motor 142 from the drive circuit 140. If desired, this
can be a self-contained system that may not need to communicate
with the processing circuit 110. However, the laser transmitter 100
will typically desire knowledge of whether or not the base unit has
actually finished its leveling function before the laser
transmitter 100 begins to function in its normal mode of operation.
In addition, the processing circuit 110 may well desire to control
the leveling motor drive circuit 140, essentially to keep it
de-energized at times when it is not critical for the base unit to
actually be attempting to level itself with respect to gravity.
[0066] Laser transmitter 100 also includes an angle encoder 150, in
a preferred embodiment. Angle encoder 150 will provide input
signals to the processing circuit 110, so that it knows exactly
where the laser transmitter is being pointed with respect to the
azimuth direction. This could be a wholly manual operation, if
desired to reduce system cost by eliminating the encoder. However,
for a fully automated system, the angle encoder 150 will be
necessary.
[0067] Laser transmitter 100 preferable will also include an
azimuth motor drive, generally designated by the reference numeral
160. Motor drive 160 will provide the proper current and voltage to
drive the azimuth motor 162, which is the motive force to aim the
laser transmitter. This again could be part of a self-contained
system, working with the angle encoder 150; however, on FIG. 2, it
is illustrated as being controlled by the processing circuit
110.
[0068] Laser transmitter 100 also includes a laser light source
driver circuit 170, which provides the current and voltage to drive
a laser light source 172. This typically will be a laser diode,
although it could be an other type of laser light beam emitter, if
desired. As described above, the laser light source will typically
be emitting visible light, although a non-visible light source
could be desirable for certain applications, and a laser light
source emitting infrared light could be used in that situation. The
laser source driver 170 is controlled by processing circuit 110 in
the configuration illustrated on FIG. 2.
[0069] The laser transmitter 100 will typically be a "fan beam"
laser transmitter for use in the system 10. However, it will be
understood that other types of laser light sources could be used,
including a rotating laser beam, if desired. However, there must be
some minimum amount of divergence to create a laser light "plane"
so that the laser light will at least intersect the floor surface
of a jobsite, and preferably also intersect a ceiling surface for
enclosed spaces on jobsites. The system 10 will have many uses,
even if the laser light source only is pointing at a floor surface,
but system 10 expands its usefulness if the divergence angle of the
laser plane is designed to intersect not only the floor, but also
the ceiling of the enclosed space. In this description, it will be
assumed that the laser light source is a fan beam laser, and so a
continuous plane of laser light is being emitted by each laser
transmitter 100 at both base units 20 and 30.
[0070] Referring now to FIG. 3, a laser receiver generally
designated by the reference numeral 200 is depicted in block
diagram form. Laser receiver 200 includes a processing circuit 210,
which has associated RAM 212, ROM 214, and an input/output
interface circuit 216. These devices communication with the
processing circuit 210 over a bus 218, typically including at least
data and address lines.
[0071] The input/output circuit 216 receives signals from some type
of photosensor. On FIG. 3 two different types of photosensors are
depicted. A "butt end" photosensor is depicted at the reference
numeral 220, and this assumes there are only two individual
photocells. Each of these photocells of the photosensor 220
provides an electrical signal to a gain stage 222. The output of
the gain stage is directed to a demodulation circuit 224, and the
output of that circuit directs a signal to the I/O circuit 216. It
will be understood that a demodulation circuit will not be
necessary unless the laser light signals themselves are of a
modulated type of signal. In most applications for the system 10, a
modulated laser light signal will be desirable, and thus a
demodulation circuit 224 will be used in those instances.
[0072] The second type of photosensor is depicted as a portion of
what is sometimes referred to as a "rod sensor" and is designated
by the reference numeral 230. An exemplary "full" rod sensor is
disclosed in U.S. Pat. No. 7,110,092, which issued on Sep. 19,
2006, which disclosure is incorporated by reference herein in its
entirety. It will be understood that the second photosensor 230 can
comprise virtually any type of "all-around" light-sensing device,
i.e., a photosensor that is able to detect incoming light from
essentially any angle.
[0073] A typical "full" rod sensor would have two photocells, one
at each end of the light-conducting rod. However, rod sensor 230
has only a single photocell in FIG. 3, which produces an electrical
signal that is directed to a gain stage 232, which outputs a signal
to a demodulation stage 234. As in the other type of photosensor
circuit described above, the demodulation circuit 234 is only
necessary if the laser light source emits a modulated signal, which
would be typical for this system 10.
[0074] An interface circuit 240 is also provided in the laser
receiver 200. This is a separate interface circuit from the I/O
circuit 216. Interface circuit 240 communicates position
information to the laser transmitter communications port B, which
will be used in helping "aim" the laser transmitters during a
portion of the set-up mode of operation, as discussed below.
[0075] Referring now to FIG. 4, a block diagram is provided for a
remote unit, which is generally designated by the reference numeral
300. Remote unit 300 includes a processing circuit 310, with
associated RAM 312, ROM 314, some type of bulk memory or external
memory 316, and an input/output circuit 318. These circuits are all
in communication with the processing circuit 310 via a bus 315,
which normally would carry data signals and address signals, and
other types of microprocessor signals, such as interrupts.
[0076] The bulk memory 316 could be a disk drive, or perhaps some
type of flash memory. If in the form of flash memory, it could be
an external memory device (such as a "portable memory device") that
can plug into the remote unit, via a USB port, for example.
[0077] In that situation, there would be a USB interface between
the bulk memory device 316 and the bus 315.
[0078] The I/O circuit 318 will be in communication with a first
communications port 320, which is designated as communications port
"X" on FIG. 4. Communications port 320 includes a transmitter
circuit 322, and a receiver circuit 324. Communications port 320 is
designed to communication with the base units 20 and 30, typically
using a wireless signal via a wireless pathway 326 (as noted on
FIG. 4). As described in greater detail below, the base units 20
and 30 will communicate azimuth angular information with the remote
unit, and that information arrives via the wireless path 326 to and
from communications port 320.
[0079] A second communications port 330 is included in remote unit
300, and this is designated as communications port "Y" on FIG. 4.
Communications port 330 includes a transmitter circuit 322 and
receiver circuit 334. This communications port 330 is provided to
exchange information with the architect computer 50, via a
communication link 336. On FIG. 4, communication link 336 is
depicted as a wireless link, although it certainly could be
constructed by use of an electrical cable or an optical cable, if
desired. Communications port 330 will exchange floor layout data
with the architect computer 50; more specifically, it can receive a
floor plan and store it in the bulk memory circuit 316. In
addition, if the remote unit 300 receives information about a new
or "unknown" point of interest in the physical jobsite floor plan,
then that information can not only be saved in the bulk memory
circuit 316, but could be also communicated back to the architect
computer 50, via the communications port 330 to be placed in the
original floor plan. Or, a revised floor plan (which includes the
new point of interest) can be saved as a file in bulk memory
circuit 316, and that entire file could be transferred to the
architect computer 50.
[0080] It will be understood that the architect computer 50 could
comprise a "fixed" unit that essentially remains in the architect's
office, and passes data to the remote unit 300 while the remote
unit is physically at the office, or perhaps they remotely
communicate with one another via a wide area network, such as the
Internet. Alternatively, the architect computer 50 could comprise a
"portable" unit that is transported to the jobsite, and
communicates with portable unit 300 while on site. Finally, as
portable computers become even smaller in physical size, it is more
likely that the portable unit and the architect computer will
eventually become merged into a single device.
[0081] A display driver circuit 340 is in communication with the
I/O circuit 318. Display driver circuit 340 provides the correct
interface and data signals for a display 342 that is part of remote
unit 300. If remote unit 300 is a laptop computer, for example,
then this would be the standard display seen in most laptop
computers. Or, perhaps the remote unit 300 is a calculator-sized
computing device, such as a PDA (Personal Digital Assistant), in
which case the display would be a much smaller physical device.
Display 342 could be a touch screen display, if desired.
[0082] One example of a type of remote unit that could work in this
system (with some modification) is the portable "layout manager,"
which is an existing hand held computer sold by Trimble Navigation
Limited, Model Number LM80. It should be noted that one cannot
simply take the LM80 and immediately use it as a remote unit in the
present system; the software must be modified to perform the
necessary calculations, which are described below. In addition, the
input/output circuits must be modified to be able to communicate
commands and data both to and from the base units.
[0083] A keypad driver circuit 350 is in communication with I/O
circuit 318. Keypad driver circuit 350 controls the signals that
interface to an input sensing device 352, such as a keypad, as
depicted on FIG. 4. Again, if the display 342 is of a touch screen
type, then there may not be a separate keypad on remote unit 300,
because most of the command or data input functions will be
available by touching the display itself. There may be some type of
power on/off switch, but that would not necessarily be considered a
true keypad (and typically would not be used for entering
data).
[0084] Details of System Methodology
[0085] Referring now to FIG. 5, a flow chart is provided for a
routine that performs a system set-up function. Beginning with an
initialization step 400, the user positions two base units, and
then places both base units into their set-up mode of operation, at
a step 402 on FIG. 5. Beginning at a step 410, the two base units
are aligned using a predetermined routine. An example of how this
alignment occurs is provided below, and also is illustrated
beginning at FIG. 14.
[0086] At a step 412, the alignment routine begins by aiming the
laser beam of base unit "A" at a target that is located on base
unit "B." A similar situation occurs at the opposite laser
transmitter; at a step 414 the laser beam of base unit "B" is aimed
at a target on the base unit "A." (See a more detailed description
below, in connection with FIGS. 14-19.)
[0087] At a step 416, the angular aim of both base units is
adjusted until their laser beams create an alignment axis. If a
manual or visual alignment is going to be used, then the logic flow
travels to a step 418. Alternatively, an automatic alignment occurs
if there are laser receivers mounted to the base units; in that
situation the logic flow is directed to a step 420.
[0088] Once an alignment axis is created, a step 422 allows the
operator to enter data from the angular encoders to the remote
unit. The user would typically be handling the remote unit itself
(i.e., remote unit 420), and by entering a command on its keypad or
touch screen, the remote unit 40 will request the alignment
information from both base units, and then store that angular
encoder information into the memory circuit 316 of remote unit 300.
Once this has occurred, the two laser transmitters of base units
"A" and "B" are situated in a fixed relationship with respect to
one another, and are ready for a floor layout session. The logic
flow now arrives at a step 430, which begins a routine that
establishes the benchmarks.
[0089] To establish benchmarks, a step 432 requires the user to
visually locate two benchmark points on the floor surface at the
jobsite. At a step 434, the user selects a first benchmark point,
designated "B1." The user now aims both laser beams for base unit A
and base unit B at this point B1. This will be very easy to do,
because the laser beams are actually vertical laser planes, and if
the light emanating from the laser transmitters comprises visible
light, then there will be a thin line of visible light crossing the
floor surface from each of the base units A and B. After both laser
beams are aimed directly at the first benchmark point B1, then
there will be an intersection of the two laser beams exactly at
benchmark point B1. Once that occurs, the user can enter the aiming
data for point B1 into the remote unit at a step 436. This
establishes the angular relationship between the two base units A
and B and the first benchmark point B1.
[0090] The user now selects a second benchmark point "B2," at a
step 440. Both laser beams from both base units are now aimed at
point B2, in a similar fashion to that described above for
benchmark point B1, at step 434. After both laser beams are
correctly pointed, there will be a visible line intersection
exactly at benchmark point B2, and the user will easily see this if
the laser beams are emanating visible light. Once that has
occurred, the user can enter the point B2 aiming data into the
remote unit, at a step 442.
[0091] Once the remote unit has both sets of aiming data for both
benchmark points B1 and B2, then a step 450 allows the remote unit
to calculate the coordinates of benchmark points B1 and B2 on the
virtual floor plan that is contained in the memory circuit 316 of
the remote unit 300, using these base unit positions. These
calculations can use a set of example equations that are provided
hereinbelow:
[0092] The following are general case calculations for setting up
the system. It is expected that the two transmitters will be placed
in some convenient locations for the job site. The axis between the
two transmitters will be established by aligning the fan beams
relative to each other. It will be desired to calculate the
distance between the two transmitters. See, FIG. 22 for a diagram
that illustrates the relationship of physical points and angles
involved in the set-up routine.
DEFINITIONS
[0093] T1 Transmitter 1 [0094] T2 Transmitter 2 [0095] B1 Benchmark
1 (Known point--previously established) [0096] B2 Benchmark 2
(Known point--previously established) [0097] A1 Axis between the
two transmitters
[0098] Knowns: [0099] D Distance between Benchmark 1 and Benchmark
2 [0100] A1 The axis between the two transmitters. [0101] .alpha.
Angle transmitter 1 measures from the axis A1 to Benchmark 2 [0102]
.gamma. Angle transmitter 2 measures from the axis A1 to Benchmark
1 [0103] .beta. Angle Transmitter 1 measures between Benchmark 1
and Benchmark 2 [0104] .delta. Angle Transmitter 2 measures between
Benchmark 1 and Benchmark 2
[0105] It is desired to find the distance `d` between the
transmitters T1 and T2:
d sin ( .pi. - .alpha. - .beta. - .gamma. ) = a sin ( .gamma. ) tan
( .gamma. ) = a sin ( .alpha. + .beta. ) r Eq . 1 r = a sin (
.alpha. + .beta. ) tan ( .gamma. ) Eq . 3 d sin ( .pi. - .alpha. -
.gamma. - .delta. ) = b sin ( .alpha. ) tan ( .alpha. ) = b sin (
.gamma. + .delta. ) s Eq . 2 s = b sin ( .gamma. + .delta. ) tan (
.alpha. ) Eq . 4 sin ( .rho. ) = b sin ( .gamma. + .delta. ) - a
sin ( .alpha. + .beta. ) D Eq . 5 r + s - d = D cos ( .rho. ) Eq .
6 ##EQU00001##
[0106] From Eq. 1:
a = d sin ( .gamma. ) sin ( .pi. - .alpha. - .beta. - .delta. )
##EQU00002##
[0107] Substitute Eq. 1 into Eq. 3:
r = d sin ( .gamma. ) sin ( .alpha. + .beta. ) sin ( .pi. - .alpha.
- .beta. - .gamma. ) tan ( .gamma. ) Eq . 7 ##EQU00003##
[0108] From Eq. 2:
b = d sin ( .alpha. ) sin ( .pi. - .alpha. - .gamma. - .delta. )
##EQU00004##
[0109] Substitute Eq. 2 into Eq. 4:
s = d sin ( .alpha. ) sin ( .gamma. + .delta. ) sin ( .pi. -
.alpha. - .gamma. - .delta. ) tan ( .alpha. ) Eq . 8
##EQU00005##
[0110] Substitute Eq. 1 and Eq. 2 into Eq. 5:
.rho. = sin - 1 [ d sin ( .alpha. ) sin ( .gamma. + .delta. ) D sin
( .pi. - .alpha. - .gamma. - .delta. ) - d sin ( .gamma. ) sin (
.alpha. + .beta. ) D sin ( .pi. - .alpha. - .beta. - .gamma. ) ] Eq
. 9 ##EQU00006##
[0111] Substitute Eq. 7 and Eq. 8 into Eq. 6:
d = D cos ( .rho. ) sin ( .gamma. ) sin ( .alpha. + .beta. ) sin (
.pi. - .alpha. - .beta. - .gamma. ) tan ( .gamma. ) + sin ( .alpha.
) sin ( .gamma. + .delta. ) sin ( .pi. - .alpha. - .gamma. -
.delta. ) tan ( .alpha. ) - 1 Eq . 10 a ##EQU00007##
[0112] Eq. 10a can also be written:
d = D cos ( .rho. ) sin ( .pi. - .alpha. - .beta. - .gamma. ) sin (
.pi. - .alpha. - .gamma. - .delta. ) tan ( .gamma. ) tan ( .alpha.
) sin ( .gamma. ) sin ( .alpha. + .beta. ) sin ( .pi. - .alpha. -
.gamma. - .delta. ) tan ( .alpha. ) + sin ( .alpha. ) sin ( .gamma.
+ .delta. ) sin ( .pi. - .alpha. - .beta. - .gamma. ) tan ( .gamma.
) - sin ( .pi. - .alpha. - .beta. - .gamma. ) sin ( .pi. - .alpha.
- .gamma. - .delta. ) tan ( .gamma. ) tan ( .alpha. ) Eq . 10 b
##EQU00008##
[0113] At this point is can be seen that two independent equations
exist here: Eq. 9 and Eq. 10. These can be solved simultaneously
through various numerical method techniques.
[0114] Once the calculations have been completed and both
benchmarks have been entered into remote unit 300, the logic flow
arrives at a step 452, in which the system set-up routine is now
completed. The positions of both base units A and B have been
"registered" or "mapped" into the virtual floor plan, which is
stored either in the bulk memory circuit 316 of the remote unit 300
(which could be a removable flash memory chip), or is stored in the
architect computer 50, which is in communication with the remote
unit 300 via its communication port Y (at 320). The system is now
ready to locate other points on the floor plan.
[0115] It should be noted that, if the two base units 20 and 30 had
been previously positioned at the same locations where they
currently rest, then in theory, the set-up procedure of the flow
chart of FIG. 5 would not be necessary now. However, the user may
desire to verify those base unit positions, to be certain that one
of the base units had not been moved without knowledge of the user.
Their positions can be easily verified by commanding the two base
units to "aim" at the benchmark points, one benchmark at a time. If
the base units had not be moved, then the laser light lines
projected by laser transmitters 22 and 32 will form intersecting
lines exactly at the correct physical locations on the jobsite
floor surface, and this quickly verifies the set-up parameters.
[0116] Referring now to FIG. 6, a flow chart is provided for a
routine to find a "known" point on the virtual floor plan. The
routine begins at a step 500, in which two base units and two known
benchmarks have been established on the virtual floor plan of the
remote unit 300. The logic flow now is directed to a step 510, in
which the user enters coordinates for a point of interest. This
entry is done via either an input sensing device 352 (e.g., a
keypad), or via a touch screen display (such as display 342) of the
remote unit 300. These coordinates can be entered using the virtual
floor plan that was on the architect's computer 50, and those
coordinates will be automatically translated to a set of aiming
data for the base units that contain the laser transmitters.
[0117] In essence, the coordinates for this known point of interest
have already been "predetermined" as far as the virtual floor plan
is concerned; the known point of interest has already been
"registered" or "mapped" in the memory of the computer that holds
the virtual floor plan. In previous (conventional) layout systems,
the difficult part has been to now identify, on the actual physical
jobsite floor surface, exactly where that known point of interest
is located, so that work may be performed at the correct
position.
[0118] The first laser beam of base unit "A" is slewed to aim the
laser beam at the entered coordinates, at a step 512. In a similar
manner, a step 514 causes the laser beam to be slewed for the base
unit "B" to aim at the same set of entered coordinates. After this
has occurred, the two laser planes from base units A and B will
intersect on the floor surface at the designated coordinates. The
user, at a step 516, can now visually locate the intersecting point
on the floor surface, and can commence work at that point.
[0119] The logic flow now arrives at a decision step 520, where it
determines if there will be work at the ceiling level. If not, the
logic flow is directed to a step 530. If the answer is YES, then
the user will visually locate the intersecting point of the two
laser planes on the ceiling surface at a step 522. The user will
now be able to commence work at that point. This would be useful
for installing sprinklers, smoke detectors, or lighting fixtures,
for example, as per the architect's plan.
[0120] The logic flow now arrives at a decision step 530, where it
determines whether or not there will be work along a vertical wall.
If not, then the logic flow is directed to a step 534. If the
answer is YES, then the user will visually locate the intersecting
line on the wall surface at a step 532. This is the implied plumb
line that exists between the floor and ceiling intersecting points
of the two laser planes. Now that a wall surface has the vertical
plumb line visible along the wall's surface, the user can commence
work along that line. This can be useful for placing electrical
outlets, or for framing, or even for positioning the wall in the
first place.
[0121] The logic flow now arrives at a step 534, and the routine is
now completed for this location. A decision step 540 now determines
whether or not the user is ready for another point of interest. If
not, the logic flow is directed to a step 542, where this routine
is completed. If the user is ready for another point of interest,
then the logic flow is directed back to step 510, which allows the
user to enter coordinates for a new point of interest on the remote
unit 300.
[0122] An example set of position calculations is provided below.
This calculation set describes a method to solve for the aiming
angles when laying out the location of a known point of interest
once the system is set up; it solves for the angles each
transmitter must drive to in order to present a point of interest
that is desired to be found. See, FIG. 23 for a diagram that
illustrates the relationship of physical points and angles involved
in the routine for locating a known point of interest.
DEFINITIONS
[0123] T1 Transmitter 1 [0124] T2 Transmitter 2 [0125] B1 Benchmark
1 (Known point--previously established) [0126] B2 Benchmark 2
(Known point--previously established) [0127] A1 Axis between the
two transmitters
[0128] Knowns: [0129] d Distance between transmitters [0130] A:
(X.sub.A, Y.sub.A) Coordinates of the Point of Interest to be
Found
[0131] Process: [0132] 1) Enter the coordinates of the Point of
interest into the system remote. [0133] 2) Transmitters 1 and 2
drive to the corresponding angles .theta. and .phi. needed to
present point A: (X.sub.A, Y.sub.A). [0134] 3) Visually locate
where the planes intersect. From the diagram: a=X.sub.A and
b=Y.sub.A
Solving for .theta. and .phi.:
[0135] .theta. = tan - 1 ( b a ) ##EQU00009## .phi. = tan - 1 ( b d
- a ) ##EQU00009.2##
[0136] Referring now to FIG. 7, a routine to enter an "unknown"
point is provided as a flow chart. The routine begins at a step
600, in which two base units and two known benchmarks have already
been established on the virtual floor plan at this step. A step 610
now locates a "new" physical point of interest on a surface that is
within the working floor plan. This new point of interest is not
already plotted on the virtual floor plan--if it was, it would not
be "unknown." Instead, this new point is something that the user
has decided should be now plotted on the virtual floor plan, and it
is a physical point that the user can actually see, and that he/she
wants to now have memorialized within the floor plan computer
files.
[0137] After the new, point of interest has been physically located
at step 610, a step 612 requires the user to aim the laser beam of
base unit "A" at this point of interest. This means that the user
must command (or manually slew) the laser beam directly at the
point of interest, so that the plane of laser light creates a line
along the floor surface (assuming this point is on the floor
surface) until that line visually crosses the point of
interest.
[0138] After base unit "A" has been aimed at step 612, a step 614
now requires the user to aim the laser beam of base unit "B" at the
same new point of interest. Again, the laser plane from base unit
"B" will create a line of laser light along the floor surface
(again assuming this is a point on the floor surface), and this
creates a visible line that emanates away from base unit "B" and,
after being properly aimed, the laser light will visually cross the
new point of interest. At the end of this aiming phase in step 614,
both laser planes should now intersect (as visible light lines on
the floor surface) exactly at the point of interest.
[0139] The angular encoders will now have azimuth information that
can be stored, and a step 620 enters data from the angular encoders
of both base units into the remote unit. (This would typically
occur via a user command entered on the remote unit.) Once the
remote unit has this data, a step 622 causes the remote unit to
execute a reverse calculation to plot the coordinates for this
point of interest on the virtual floor plan. Once that has
occurred, the unknown point of interest is now "registered" on the
virtual floor plan, and that point of interest essentially becomes
a "known" point of interest and thereby can be "found" later, even
if the base units 20 and 30 are moved to other locations. A step
624 now is reached, at which the routine has been completed for
this particular location at this point of interest).
[0140] Alternatively, if the base units do not have azimuth
encoders, then they will be equipped with a visual angle scale that
the user can see on an upper surface of the base units. After the
user has (manually) aimed the laser transmitter for each base unit
(at steps 612 and 614), then he/she may read the azimuth angular
displacement for both laser transmitters, and that information can
then be manually entered into the remote unit at step 620 (using
its input sensing device 352). Once the remote unit has this data,
steps 622 and 624 are performed, as described above.
[0141] A decision step 630 now determines whether or not the user
is ready for another "new" point of interest. If not, then the
entire routine of FIG. 7 has been completed at a step 632. On the
other hand, if the user has another point of interest to be plotted
at this time, then the logic flow is directed back to step 610, in
which the user locates that other physical point of interest on a
surface that is within the working floor plan.
[0142] By using the routine depicted in the steps of the flow chart
on FIG. 7, a user can easily choose any point of interest on the
jobsite that is within a non-interrupted view of both laser
transmitters in both base units. Once the user has located that
physical point, it is a simple matter to aim both laser
transmitters directly at that point to create two intersecting
lines of laser light from the laser planes emitted by the two laser
transmitters. This is very easy to do, because the user can see
everything that is going on, assuming the laser transmitters are
emitting visible light. Even if the light is infrared, for example,
the user could be utilizing special night-vision goggles to locate
these points, if desired. This non-visible light scenario might be
quite useful for applications that are to occur in the dark, and
might even have military applications (for plotting positions of
mines in a minefield, for example).
[0143] This routine of FIG. 7 can be performed much more quickly
than a typical surveying function that is being performed countless
times on jobsites using earlier technology. No type of surveyor's
rod is necessary, and such a rod would not need to be positioned
and plumbed for each new point of interest, such as is required in
many of the systems using available conventional technology.
[0144] If the user selects a point that is not within direct
visible range of one of the laser transmitters, it is a simple
matter to move that particular laser transmitter to a different
location within the virtual floor plan and re-establish its set-up
function using the routine illustrated as a flow chart in FIG. 5.
Once the laser transmitter has been placed at a new location, its
position can easily be established with benchmarks that are always
available on a new jobsite, and once everything has been registered
with the remote unit, the user can directly begin to enter unknown
points, using the flow chart of FIG. 7.
[0145] An example set of reverse calculations is provided below.
This calculation set describes a method to solve for the
coordinates for the location of an unknown point of interest once
the system is set up. See, FIG. 24 for a diagram that illustrates
the relationship of physical points and angles involved in the
routine for entering an unknown point of interest.
DEFINITIONS
[0146] T1 Transmitter 1 [0147] T2 Transmitter 2 [0148] B1 Benchmark
1 (Known point--previously established) [0149] B2 Benchmark 2
(Known point--previously established) [0150] A1 Axis between the
two transmitters
[0151] Knowns: [0152] d Distance between transmitters [0153]
.theta. Angle measured by transmitter 1 from the axis between
transmitters and the point of interest [0154] .phi. Angle measured
by transmitter 2 from the axis between transmitters and the point
of interest
[0155] Process: [0156] 1) Command each transmitter to place each
respective fan beam over the point of interest. [0157] 2)
Transmitters 1 and 2 measure the angles .theta. and .phi.. [0158]
3) Since d is known from the system setup, the coordinates of point
a can be calculated.
[0159] From the diagram:
y 0 = d 1 tan ( .theta. ) + 1 tan ( .phi. ) ##EQU00010##
[0160] This can be written:
y 0 = d tan ( .phi. ) tan ( .theta. ) tan ( .theta. ) + tan ( .phi.
) ##EQU00011## And : ##EQU00011.2## x 0 = y 0 tan ( .theta. )
##EQU00011.3##
[0161] Further Operating Details
[0162] Referring now to FIG. 8, a diagrammatic view is provided for
the main "mechanical" components found in a base unit, including a
laser transmitter and a laser receiver. The base unit is generally
designated by the reference numeral 100, and includes a leveling
platform at the bottom of the structure, upon which is mounted a
rotational unit for adjusting the azimuth angle of the laser
transmitter. The leveling platform includes two leveling motors
142, a level sensor 144 (e.g., some type of electronic gravity
sensor), and a pivot 146. Above the leveling motors 142, are
leadscrews 148, and the horizontal leveling platform is mounted on
the top of the leadscrews 148.
[0163] It will be understood that a manual leveling platform could
be provided with base unit 100, rather than the "automatic"
leveling platform described in the previous paragraph. Such a
manual leveling platform could use a pendulum or a visible bubble,
for example, and there would be no automatic gravity sensing device
or leveling motor drive.
[0164] On the upper surface of the leveling platform is the azimuth
motor 162, which has output shaft and a pinion gear 164, which
meshes with a spur gear 166. The spur gear has an output shaft that
is vertical, which runs through an encoder disc subassembly 152 and
up to a second wheel or disc that includes a pair of butt cell
photosensors 220. The encoder disc subassembly 152 typically has
some type of visible markings that can be detected by an encoder
readhead, which is located along the outer perimeter of the encoder
disc. On FIG. 8, the encoder readhead is designated by reference
numeral 154, and the overall angle encoder system 150 includes both
the encoder disc subassembly 152 and the encoder readhead 154.
Typical optical encoders have a fixed portion and a rotatable
portion, as depicted on FIG. 8 by the two parallel disc structures
in subassembly 152.
[0165] A laser diode 172 is mounted (in this diagrammatic view) in
the horizontal direction, and it emits a laser light beam through a
collimating lens 174, and that laser light travels through a
cylinder lens 176 to create an output fan beam 178. The fan beam
178 is diagrammatically presented on FIG. 8 as a diverging plane of
laser light.
[0166] In this arrangement, the azimuth motor 164 turns the aiming
direction of the fan beam laser plane of light 178, and this
simultaneously moves the butt cell photosensors 220 and a portion
of the encoder disc subassembly 152. In a typical arrangement, the
split between the butt cell photosensors will be along the same
vertical line as the edge view of the fan beam laser plane of light
178. However, it should be noted that the butt cell photosensors
220 could be somewhat offset from the centerline of the plane of
laser light 178, and the calculations for determining positions of
various points in the floor layout system could be adjusted by
those offset calculations, especially for determining/establishing
an alignment axis. This optional arrangement, sometimes referred to
as "characterizing" the photosensors, can make it somewhat easier
to construct the base unit, if desired.
[0167] A second photosensor is provided on FIG. 8. This is a "rod"
sensor, and is depicted at reference numeral 230. In this rod
sensor, however, there is only a single photocell at 236. Although
a typical position-sensing rod sensor would have two photocells (as
depicted in FIG. 3), in the configuration of FIG. 8, the
information being sought only requires a single photocell. In the
base unit 100, the information being sought is whether or not laser
light is impacting the rod sensor cylindrical surface, and if so, a
single photocell at 236 will detect that event. On the other hand,
if greater sensitivity is desired, or if the manufacturer wishes to
use a standard rod sensor that already has two photocells mounted
to the cylindrical rod (one on each end), then a standard rod
sensor could be used, as depicted on FIG. 3.
[0168] As indicated on FIG. 8, the azimuth motor drive 162 can
rotate the entire upper portion of the base unit in the horizontal
plane; i.e., the rotational axis is essentially vertical, once the
leveling platform has adjusted itself to making the system
substantially horizontal with respect to gravity.
[0169] An alternative arrangement could be used to build a lesser
expensive base unit 100. The photosensor 220 could be replaced by a
small reflector that is precisely positioned to be in vertical
alignment with the centerline of the plane of laser light 178. In
this alternative embodiment, the opposite laser transmitter would
have to be manually aimed at the reflector, when determining an
alignment axis. This certainly would be more difficult to set up
than the automated procedure that is described below, but it is
possible, particularly for short-range situations in which the
distance between the base units is relatively small. The laser
receivers 24 and 34 could be entirely eliminated in this
alternative embodiment.
[0170] Another way to reduce system cost is to eliminate the
automatic azimuth aiming platform altogether, and instead rely on
manual aiming of the laser transmitters for both base units. This
second alternative embodiment would save the cost of the azimuth
drive (including motor 162) and the encoder system 150. Of course,
the "aiming" azimuth angles then would have to be read manually
from an arcuate scale on the base unit, and these angles would have
to be entered manually into the remote unit by the user every time
the laser transmitter is aimed at a new benchmark point, a known
point of interest, or an unknown point of interest. The possibility
of errors in data entry would increase, even if the azimuth angles
are correctly read in the first place.
[0171] Referring now to FIGS. 9-13, a set of illustrations is
provided to more readily demonstrate the ease of use of the system
being disclosed herein. In FIG. 9, a first step for aligning the
axes of the two laser transmitters is depicted. The laser
transmitters are part of the base units 20 and 30, which are
mounted on tripods in FIG. 9. A user, generally designated by the
reference numeral 45, is depicted as holding a hand-held remote
unit 40, within the confines of an enclosed space (or room) 700.
The room 700 has a ceiling surface 710 and floor surface 712.
[0172] The laser transmitter at base unit 20 emits a laser fan
beam, which has an upper angular limit line at 722 and a lower
angular limit line at 724. The other laser transmitter at base unit
30 also emits a fan beam of laser light, and has an upper angular
limit line at 732 and a lower angular limit line at 734. The object
in this step of FIG. 9 is to align an axis 740 between the two
laser transmitters. The methodology for a detailed alignment
procedure is described below, in reference to FIGS. 14-19. At this
point in the description, it will be assumed that the alignment
axis 740 is being determined by this procedure.
[0173] FIG. 10 illustrates the next step, which aligns the two
laser transmitters to a first benchmark point (referred to on FIG.
10 as "Benchmark 1"). In FIG. 10, the interior space (or room) is
referred to as reference numeral 701. The two laser transmitters
have been aimed at the point of interest that is Benchmark 1, and
is designated by the reference numeral 752. The two base units 20
and 30 have either had their lasers manually aimed by the user, or
automatically adjusted by the user using the remote unit 40, if
azimuth positioning motors and encoders are available on base units
20 and 30. After the two laser planes have been aimed so that they
will intersect the first benchmark at 752, the laser planes will
have an appearance as illustrated on FIG. 10. The laser plane from
the fan beam laser transmitter of base unit 20 will again have
angular limit lines 722 and 724, but will also produce a visible
line along the ceiling at 726, and a similar visible line along the
floor surface at 728. In a similar manner, the laser transmitter
producing the fan beam from base unit 30 will emit angular limit
lines 732 and 734, and also produces an upper visible line along
the ceiling at 736 and a lower visible line along the floor surface
at 738.
[0174] It will be understood that, as used herein, the terms
"visible light" or "visible laser light" refer to laser light beams
that are either directly visible by the human eye (i.e., having a
wavelength in the range of approximately 430 nm to 690 nm), or
refer to laser beams that are somewhat outside of the above
"normal" range of visible acuity for human eyes, and the user is
being aided by some type of special lenses. For example, the laser
transmitters described herein could produce infrared (IR) laser
light beams if desired, and the user could be wearing night-vision
goggles; in that situation, the laser light beams would appear to
be "visible" to that user, which is more or less necessary to
properly use the alignment and location features of the system
described herein.
[0175] The two lower laser plane edges 728 and 738 will intersect
exactly at the benchmark point 752, after the two laser
transmitters have been correctly adjusted for their angular
position along the azimuth direction, and the user will be able to
visibly see that intersection point. Moreover, the two laser planes
will intersect along a vertical line 750, which will be a plumb
line if the two base units have been correctly leveled. This laser
line of intersection 750 will actually be visible if a solid
object, or some type of smoky substance, is positioned along the
line itself. At the top of the laser light line 750 will be another
visible intersection of "horizontal" lines along the ceiling, which
will be described below, in greater detail.
[0176] The third step is to align the laser transmitters for the
two base units to the second benchmark point, which is referred to
on FIG. 11 as "Benchmark 2." The interior space (or room) is
designated at the reference numeral 702 in FIG. 11. The user now is
required to move the angular positions of both laser transmitters
for the base units 20 and 30 so that they are aimed at the second
benchmark, which is designated at reference numeral 762. Both laser
transmitters continue to emit a plane of laser light, and the fan
beam thereby produced has divergence angles that are represented by
the lines 722, 724, 732, and 734. Furthermore, there will be upper
and lower visible lines along the ceiling surface and floor
surface, which again are designated by the line segments 726, 728,
736, and 738.
[0177] After the two laser transmitters have been properly aimed at
the second benchmark 762, the lower visible lines of the two laser
planes will intersect exactly at benchmark 762, and the user will
be able to visibly see that intersection point.
[0178] It will be understood that, as used herein, the phrase
"intersect exactly" at a specific point on a surface means that the
user has adjusted the laser transmitters so that their emanating
laser fan beams produce light lines that appear to be precisely
crossing that specific point. Of course, there will likely be some
small tolerance of error, and it is up to the user to make the
proper adjustments in aiming the base unit laser transmitters so
that the light lines are as close to "exactly" crossing right at
the proper location. Since the laser light lines have a discernable
width, the user cannot literally align the laser beams within some
imperceptible tiny distance, and thus, there will likely be a very
small tolerance of error in such "exact" positions of the laser
transmitter azimuth angles. However, this is a very small error
indeed, and moreover, the user will quickly become very good at
making these azimuth position changes of the laser transmitters
such that any such errors will essentially be negligible.
[0179] As in the case of FIG. 10, there will also be an
intersecting vertical line between the two laser planes, and this
intersecting line is represented at the reference numeral 760 on
FIG. 11. This intersecting line 760 is a plumb line, so long as the
two laser transmitters have been properly leveled.
[0180] After both benchmark points have had their coordinates
entered into the remote unit 40 (as per FIG. 10 and FIG. 11), the
set-up of the system has been completed. Now the user will be able
to enter other coordinates of interest into the remote unit 40, and
cause the laser transmitters to automatically aim at those
coordinates (assuming the laser transmitters are motorized and have
angular encoders). FIG. 12 illustrates such a situation, in which
the user has entered the coordinates of a floor point designated by
the reference numeral 772 on FIG. 12. The enclosed space (or room)
is designated at the reference numeral 703 on FIG. 12. The laser
transmitters have been aimed so that their fan beams each produce a
plane of laser light that is vertical, and both of these planes of
laser light intersect exactly at the point 772 along the floor
surface 712. There will also exist a vertical line of intersection
between the two laser planes at the reference numeral 770. This
will be a plumb line, as described before, so long as the laser
base units 20 and 30 have been correctly leveled. More importantly,
the two laser transmitters need to output laser planes that are
substantially vertical with respect to gravity; if that correctly
takes place, then the implied line 770 will also be substantially
vertical with respect to gravity.
[0181] Since the plumb line 770 exists as a vertical line directly
above the floor point 772, there will also be visible to the user a
ceiling transfer point that is designated by the reference numeral
774. The user will see a pair of intersecting lines at point 774,
which are produced by the two upper edges of the laser planes from
the laser transmitters of base units 20 and 30. These are the upper
edge lines of the fan laser beams along the line segments 726 and
736, which follow along the surface of the ceiling 710. This
provides the user with a virtually instantaneous transfer point
along the ceiling surface, every time the user first designates a
floor point of interest. The ceiling transfer point 774 is
automatically plumb above the floor point 772, since the implied
line 770 is truly plumb. This system allows the building designer
to lay out devices that are to be installed in the ceiling by using
the coordinates on a two-dimensional floor plan, if desired.
[0182] The technology disclosed herein automatically can take floor
points and transfer those coordinates to the ceiling; furthermore
if the building plan was a three-dimensional plan, then a ceiling
set of coordinates could first be entered instead of a floor set of
coordinates. In that mode of operation, the two laser transmitters
of base units 20 and 30 will still be able to slew automatically so
that their laser fan beams will intersect the ceiling set of
coordinates instead of the floor set of coordinates. The final
appearance will be the same, just like what is illustrated in FIG.
12. The only difference will be that the ceiling point was
determined first, instead of the floor point. There will still
exist a plumb line 770 after the ceiling point has been laid
out.
[0183] Referring now to FIG. 13, the ability of the system
disclosed herein to create a vertical plumb line of laser light
will be used advantageously. An enclosed space (or room) 704 is
depicted on FIG. 13, and the two laser transmitters of base units
20 and 30 have been aimed at a floor point 782 that is located just
along the edge of one of the walls, which is designated by the
reference numeral 714. The laser fan beams will create a visible
plumb line of laser light 780 that will be visible along the
surface of the wall 714. There also will exist a ceiling
intersecting point at 784, that is the top point of the line
segment 780 that makes up this intersecting line between the two
planes of laser light. For the implied laser plumb line 780 to be
visible along the wall surface, the wall must be positioned at or
fairly close to the intersecting point 782; this can be termed a
"proximal" relationship--the wall must have its surface 714
proximal to the point 782, or the intersecting line of laser light
780 will "miss" the wall surface, and not be visible on that wall
surface. Of course, the wall itself must be fairly plumb, or the
plumb line 780 will not properly appear along the wall's
surface.
[0184] As discussed in the previous paragraph, if a two-dimensional
floor plan is available, then the user can start with the floor
intersecting point 782 as the point of interest. On the other hand,
if a three-dimensional set of floor plans is available, and if the
ceiling intersecting point 784 has coordinates that are available
to the user, then that point could be used to cause the laser
transmitters to be aimed as depicted in FIG. 13.
[0185] After the plumb line 780 appears along the wall surface 714,
the user can use that plumb line to help align and set studded
wall. In addition, once the walls have been installed, the vertical
plumb line 780 can be used to help locate the positions for
installation of wall outlets or HVAC ducts or vents, and other
similar devices that are placed in walls of buildings.
[0186] Referring now to FIGS. 14-19, an example of a methodology
for establishing an alignment axis between two base units is
provided. Referring now to FIG. 14, the two base units 20 and 30
are emitting vertical planes of laser light in a fan beam shape, in
which the plane of laser light for base unit 20 is designated by
the reference numeral 60, and the plane of laser light from base
unit 30 is designated by the reference numeral 70. As can be seen
in FIG. 14, laser light planes 60 and 70 intersect one another, but
they are not aligned, nor do they intersect the opposite base
unit.
[0187] In FIG. 14, base unit 20 has a positioning photosensor at
64, which typically can be a "butt cell" set of photocells that are
precisely aligned to the center of the emitted laser fan beam. Base
unit 20 has a second photosensor at 62 that comprises a photocell
and a cylinder lens. The cylinder lens extends vertically above the
top of the base unit structure (this is similar to element 230 on
FIG. 8), and the photocell is attached at one end of the cylinder
lens (which is similar to the photocell 236 on FIG. 8). This
photocell and cylinder lens combination 62 is roughly aligned to
the rotation center of base unit 20. (It does not need to be
precisely aligned. Photosensor 62 provides "gross" alignment
sensing capability for detecting the laser beams of the other laser
transmitter, from base unit 30.)
[0188] In a similar fashion, base unit 30 also includes a
positioning photosensor 74 which typically can be a "butt cell"
array of photocells, which are precisely aligned to the center of
the emitted laser fan beam 70. (Note: this "precise" alignment
could include characterizing the array of photocells to correct for
any offset, in case the position of the laser beam output and the
photosensor's null point are not perfectly aligned.) Also, base
unit 30 includes a cylinder lens and photocell combination at 72,
which is roughly (not precisely) aligned to the rotation center of
that base unit. Photosensor 72 provides "gross" alignment sensing
capability for detecting the laser beams of the other laser
transmitter, from base unit 20.
[0189] Referring now to FIG. 15, the user has entered a command so
that each base unit will begin to rotate. The purpose of this
rotation is to have the cylinder lens/photocell combination (either
62 or 72) detect the laser beam from the other base unit. In FIG.
15, it can be seen that both laser fan beams have changed position,
but neither fan beam 60 or 70 are intersecting the other base unit.
Laser fan beam 60 is rotating in the direction of an angular arc
line 66, while base unit 30 has its laser transmitter beam 70
rotating in the direction of an angular line 76.
[0190] Referring now to FIG. 16, the laser fan beam 70 has
intersected the vertical photosensor 62 of base unit 20. When this
occurs, base unit 30 can stop rotating its fan beam 70, because it
is now roughly in the correct position. However, the fan beam 60
from base unit 20 still needs to continue rotating in the direction
66. In FIG. 17, the fan beam 60 is still rotating from base unit
20, but has not yet intersected base unit 30. The fan beam 70 from
base unit 30 has stopped, and is still intersecting the vertical
photosensor 62.
[0191] Referring now to FIG. 18, the laser fan beam 60 from base
unit 20 has intersected the photosensor 72 of base unit 30, and the
laser transmitter at base unit 20 now will stop rotating. At this
time, both fan beams 60 and 70 are roughly aligned with the
opposite base units 30 and 20 respectively.
[0192] Referring now to FIG. 19, the positioning photocells 64 and
74 now come into play. Assuming these two photocells each comprise
a pair of butt cell photosensors, they will have a deadband width
between the two photosensitivity areas of the butt cell
arrangement, and this deadband width is the desired position that
will be sought by the two laser fan beams 60 and 70. Using the
positioning photocells 64 and 74, the laser receivers on the two
base units 20 and 30 will be able to determine the exact position
of the laser strike of the fan beams 60 and 70 within a very small
tolerance. The output signals from the laser receivers can be used
to command the azimuth positioning motors of both laser
transmitters for the base units 20 and 30 to move in small amounts
until the vertical edge of the laser planes 60 and 70 are striking
the butt cell deadband positions.
[0193] The butt cell deadband width can be made quite small,
perhaps as small as 0.005 inches, if desired. In FIG. 19, the two
laser transmitters are rotated iteratively until each of their fan
beams are striking within the deadband width of the butt cells on
the opposite base unit. This will now provide a very precise
alignment axis between the two base units 20 and 30.
[0194] Another benefit of the technology disclosed herein is
illustrated on FIGS. 20 and 21. FIG. 20 illustrates a conventional
(prior art) laser pointing system that is currently used for floor
layout procedures. This prior art system is generally designated by
the reference numeral 800, and it includes a laser transmitter 810
that is mounted on a tripod, and this assembly is placed on a floor
surface 812. This pointing laser system is designed to literally
point its laser beam 820 directly at a particular spot on the floor
surface 812, and that spot visually designates the point of
interest for the user. This system will work, so long as the floor
surface is actually flat and horizontal within the tolerance
required for the laser pointer system to successfully designate the
point of interest.
[0195] However, if there is any kind of unevenness in the floor,
such as a depression that is designated by the reference numeral
814, then the accuracy of laser pointing system 800 is completely
thrown off. It will be understood that the depression 814 could
just as easily be a protrusion in the floor surface, and that would
also negatively impact the accuracy of the system 800.
[0196] The reference numeral 822 designates the true position for
the point of interest on the floor surface where laser beam 820 is
attempting to designate that position. However, because of the
depression in the floor at 814, the projected point on this uneven
surface is at a different physical location in the horizontal
direction, which is designated by the reference numeral 824. This
causes a position error that is designated by the reference numeral
830. Depending upon the horizontal distance between the true
position 822 and the position of the laser transmitter 810, the
position error 830 can be significant, and will render the system
useless for its intended accuracy.
[0197] Referring now to FIG. 21, the technology disclosed herein
can be used with two laser transmitters, as described above, and
this type of system is generally designated by the reference
numeral 900. A first laser transmitter is at 910, and a second
laser transmitter is at 911. Laser transmitters 910 and 911 are
both mounted on tripods, and both emit a laser fan beam (in this
example), in which the fan beam for laser transmitter 910 is
designated by the reference numeral 920, and the fan beam for laser
transmitter 911 is designated by the reference numeral 921.
[0198] Both laser transmitters are positioned on a floor surface,
which is generally designated by the reference numeral 912. A point
of interest is entered into the system that controls the azimuth of
both laser transmitters 910 and 911, and therefore, they will be
aimed at the correct location on the floor surface. On FIG. 21, the
true position of the point of interest is designated by the
reference numeral 922. It so happens that the point of interest 922
lies in a depression in the floor, which is designated by the
reference numeral 914. However, the vertical planes of the two
laser fan beams 920 and 921 intersect in a vertical plumb line at
950, and this plumb line will run from its uppermost limit at the
top edge of the laser fan beams 920 and 921 down to its lowermost
limit (along line 950), which intersects the floor surface in the
depression 914, at a point 924.
[0199] Because of the way system 900 operates to create the plumb
line 950, the indicated position of the point of interest at 924
will fall exactly at the true position of the point of interest at
922. Therefore, no error will occur between the true position 922
and the point that is projected onto the floor surface 924, even
when that projected point falls within a depression, such as the
depression 914. This will also be true if, instead of a depression,
there is a protrusion in the floor surface. This feature is a very
significant advantage provided by the technology disclosed
herein.
[0200] It will be understood that some of the logical operations
described in relation to the flow charts of FIGS. 5-7 can be
implemented in electronic equipment using sequential logic (such as
by using microprocessor technology), or using a logic state
machine, or perhaps by discrete logic; it even could be implemented
using parallel processors. One preferred embodiment may use a
microprocessor or microcontroller (e.g., one of the microprocessor
110, 210, or 310) to execute software instructions that are stored
in memory cells within an ASIC. In fact, the one entire
microprocessor (or a microcontroller, for that matter), along with
RAM and executable ROM, may be contained within a single ASIC, in
one mode of the technology disclosed herein. Of course, other types
of circuitry could be used to implement these logical operations
depicted in the drawings without departing from the principles of
the technology disclosed herein. In any event, some type of
processing circuit will be provided, whether it is based on a
microprocessor, a logic state machine, by using discrete logic
elements to accomplish these tasks, or perhaps by a type of
computation device not yet invented; moreover, some type of memory
circuit will be provided, whether it is based on typical RAM chips,
EEROM chips (including Flash memory), by using discrete logic
elements to store data and other operating information (such as the
point coordinates data stored, for example, in memory elements 312
or 316), or perhaps by a type of memory device not yet
invented.
[0201] It will also be understood that the precise logical
operations depicted in the flow charts of FIGS. 5-7, and discussed
above, could be somewhat modified to perform similar, although not
exact, functions without departing from the principles of the
technology disclosed herein. The exact nature of some of the
decision steps and other commands in these flow charts are directed
toward specific future models of laser transmitter and receiver
systems, and floor layout portable computers (those involving
Trimble Navigation laser and floor layout equipment, for example)
and certainly similar, but somewhat different, steps would be taken
for use with other models or brands of laser equipment and floor
layout computer systems in many instances, with the overall
inventive results being the same.
[0202] As used herein, the term "proximal" can have a meaning of
closely positioning one physical object with a second physical
object, such that the two objects are perhaps adjacent to one
another, although it is not necessarily required that there be no
third object positioned therebetween. In the technology disclosed
herein, there may be instances in which a "male locating structure"
is to be positioned "proximal" to a "female locating structure." In
general, this could mean that the two male and female structures
are to be physically abutting one another, or this could mean that
they are "mated" to one another by way of a particular size and
shape that essentially keeps one structure oriented in a
predetermined direction and at an X-Y (e.g., horizontal and
vertical) position with respect to one another, regardless as to
whether the two male and female structures actually touch one
another along a continuous surface. Or, two structures of any size
and shape (whether male, female, or otherwise in shape) may be
located somewhat near one another, regardless if they physically
abut one another or not; or a vertical wall structure could be
positioned at or near a specific point on a horizontal floor or
ceiling surface; such a relationship could be termed "proximal."
Moreover, the term "proximal" can also have a meaning that relates
strictly to a single object, in which the single object may have
two ends, and the "distal end" is the end that is positioned
somewhat farther away from a subject point (or area) of reference,
and the "proximal end" is the other end, which would be positioned
somewhat closer to that same subject point (or area) of
reference.
[0203] All documents cited in the Background and in the Detailed
Description are, in relevant part, incorporated herein by
reference; the citation of any document is not to be construed as
an admission that it is prior art with respect to the technology
disclosed herein.
[0204] The foregoing description of a preferred embodiment has been
presented for purposes of illustration and description. It is not
intended to be exhaustive or to limit the technology disclosed
herein to the precise form disclosed, and the technology disclosed
herein may be further modified within the spirit and scope of this
disclosure. Any examples described or illustrated herein are
intended as non-limiting examples, and many modifications or
variations of the examples, or of the preferred embodiment(s), are
possible in light of the above teachings, without departing from
the spirit and scope of the technology disclosed herein. The
embodiment(s) was chosen and described in order to illustrate the
principles of the technology disclosed herein and its practical
application to thereby enable one of ordinary skill in the art to
utilize the technology disclosed herein in various embodiments and
with various modifications as are suited to particular uses
contemplated. This application is therefore intended to cover any
variations, uses, or adaptations of the technology disclosed herein
using its general principles. Further, this application is intended
to cover such departures from the present disclosure as come within
known or customary practice in the art to which this technology
disclosed herein pertains and which fall within the limits of the
to appended claims.
* * * * *