Laser level meter system with automatic detector alignment

Abstract

Various laser level meter systems that provide automatic alignment between a laser level meter and a detector are shown. In one example, a laser level system including a laser level and a detector uses more than one pairing frequency to identify between the laser level and the detector. The laser level and the detector will select one of the pairing frequencies, and then the detector will determine whether the laser frequency matches the selected pairing frequency and send a control signal to the laser level in response to the laser beam having the selected pairing frequency. The detector does not send the control signal if the detector determines that the laser beam frequency does not match the selected pairing frequency.

Description

[0001] Cross - reference to Related Patent Applications

[0002] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 513,652, filed on July 14, 2023, which is incorporated herein by reference in its entirety.

[0003] Background of the Utility Model

[0004] This utility model generally relates to the field of tools. Specifically, this utility model relates to a laser projection device, such as a plane laser level that projects one or more lasers onto a workpiece or the surface of a workpiece. Summary of the Utility Model

[0005] One embodiment of the present utility model relates to a laser level system. The laser level system includes a laser level and a detector. The detector includes a laser sensor. The laser level is configured to emit a plane laser beam and rotate relative to the detector such that the plane laser beam crosses the detector. The laser level and the detector are configured to select a first paired frequency from a set of paired frequencies. When the plane laser beam is incident on the laser sensor, the detector determines the frequency of the incident plane laser beam and compares the frequency with the first paired frequency. When the detector determines that the incident plane laser beam is at the same frequency as the paired frequency, the detector identifies the laser level, and the detector generates a control signal based on the plane laser beam.

[0006] Another embodiment of the present utility model relates to a laser level alignment system. The laser level alignment system includes a detector and a laser level. The detector includes a detector panel. The laser level is configured to emit a laser beam and rotate relative to the detector such that the laser beam crosses the detector. The detector and the laser level are configured to select a first paired frequency. When the laser beam is incident on the detector panel, the detector determines the frequency of the incident laser beam and compares the frequency with the first paired frequency. When the detector determines that the incident laser beam is at the same frequency as the first paired frequency, the detector identifies the laser level, and the detector generates a control signal based on the laser beam. When the detector determines that the frequency of the incident laser beam is different from the first paired frequency, the detector does not identify the laser level, and the detector does not generate a control signal.

[0007] Another embodiment of the present utility model relates to a method for aligning the laser from a laser level with a detector. The method includes positioning the laser level and the detector in a working environment, and the laser level and the detector select a pairing frequency. The method further includes the laser level emitting a laser at the pairing frequency and rotating the emitted laser such that the emitted laser is received at the detector. The method includes determining whether the received laser is at the pairing frequency; generating a control signal from the detector based on the received laser and the pairing frequency; and transmitting the control signal to the laser level.

[0008] In a specific embodiment, the laser level is configured such that the emitted laser beam is a vertically directed planar laser beam. In such an embodiment, the laser level is configured to rotate (e.g., rotate the laser generating component) such that the emitted vertical laser plane horizontally sweeps across the detector such that the vertical laser plane crosses the detector.

[0009] Additional features and advantages will be set forth in the following detailed description, and these additional features and advantages will be apparent to those skilled in the art from the description or will be recognized by practicing the embodiments as illustrated in the written description and / or the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary.

[0010] The accompanying drawings are included to provide a further understanding, and the drawings are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, are used to explain the principles and operations of the various embodiments. Description of the Drawings

[0011] The present application will be more fully understood from the following detailed description in conjunction with the accompanying drawings, in which like reference numerals refer to like elements, and in the drawings:

[0012] Figure 1 is a perspective view of a laser level system according to an exemplary embodiment.

[0013] Figure 2 is according to an exemplary embodiment Figure 1 of the front view of the detector of the laser level system.

[0014] Figure 3 is according to another exemplary embodiment Figure 1 of the front view of the detector of the laser level system.

[0015] Figure 4 is according to an exemplary embodiment Figure 1 of the schematic top view of the laser level system.

[0016] Figure 5 is according to an exemplary embodiment Figure 2 Schematic diagram of a detector in an environment with more than one laser level.

[0017] Figure 6 is a graphical display of multiple pairing frequencies of a detector and a laser level according to an exemplary embodiment.

[0018] Figure 7 is a flowchart showing the selection process of a detector during alignment according to an exemplary embodiment.

[0019] Figure 8 is according to an exemplary embodiment using Figure 1 Schematic diagram of a method of a laser level system. DETAILED DESCRIPTION

[0020] Referring generally to the drawings, various embodiments of a laser level system including a laser level and a laser level detector are shown. As will be generally understood, a laser level system is desired that includes a laser level and a detector and is capable of automatically controlling the projection position of the laser such that the moving laser is aligned with the detector. Providing a laser level with such functionality reduces setup time by eliminating the need for a second person to assist during setup and / or the need for a single user to repeatedly walk between points for adjustment. In a particular embodiment, the laser level automatically aligns a vertical plane beam with the detector to reduce setup time.

[0021] The applicant has made improvements to the functionality and / or control of a laser level system. In particular, the applicant has developed a laser lever system that includes a laser level and a detector and is capable of automatically controlling the projection position of the laser by the laser level such that, through a laser level-detector pairing, the laser is moved to align with the detector even in a busy work environment where multiple laser levels are in use. Compared to conventional laser level systems with automatic alignment that can detect laser dots and / or beams from non-target laser levels (i.e., unwanted and / or unpaired laser levels), the applicant has developed a system for avoiding the accidental detection of non-target laser levels. In various specific embodiments, the laser level systems discussed herein use more than one pairing or communication frequency to identify between the laser level and the detector. In such an embodiment, the laser level and the detector will randomly select one of the pairing or communication frequencies, and the detector will then respond only to laser dots and / or beams from the selected communication frequency. In various specific embodiments, each of the more than one pairing or communication frequencies corresponds to a specific laser frequency. Once the detector identifies the selected pairing frequency, the detector will communicate and / or send a control signal to the laser level. This system allows for improved automatic alignment of the laser level by preventing the detector from responding or sending a control signal to another laser level that has a laser of a frequency different from the selected pairing frequency.

[0022] Reference Figures 1 to 4 , shows a system according to an exemplary embodiment, which is shown as a laser level system 10. The laser level system 10 includes a laser level 12 and a detector 14. The laser level 12 emits a laser reference beam, which is shown as a vertical plane laser beam 18. In the illustrated embodiment, the laser level 12 is a rotary laser level configured to rotate about a vertical axis 20 such that the laser beam 18 moves in a generally horizontal direction. In various specific embodiments, the plane laser beam 18 is a vertically oriented plane laser beam. In such an embodiment, the laser level 12 is configured to rotate such that the emitted vertically oriented plane laser beam horizontally sweeps across the detector 14 such that the vertically oriented plane laser beam traverses the laser sensor detector 14.

[0023] Figure 2 Shows a detailed view of the detector 14 according to an exemplary embodiment. The laser beam 18 is shown as being aligned with a portion of the detector 14. Figure 3 Shows a detailed view of the detector 16 shown according to another exemplary embodiment. The laser beam 18 is shown as being aligned with a portion of the detector 16.

[0024] The laser level system 10 is configured such that the laser level 12 is automatically controlled to rotate the laser beam 18 to align with a portion of the detector 14 (e.g., the center of the detector photodiode array of the detector 14). Generally speaking, the laser level system 10 is configured to determine the position of the laser beam 18 relative to the detector 14 to control the rotation of the laser level 12 such that the laser beam 18 is projected at a desired position relative to the detector 14.

[0025] Reference Figure 4 , shows details of the automatic alignment process 50 according to an exemplary embodiment. When the laser level 12 and the detector 14 are aligned, the laser beam 18 from the laser level 12 rotates relatively slowly (e.g., at 10 RPM) such that the laser beam 18 traverses the detector panel 22 of the detector 14. In a particular embodiment, the laser 18 rotates between 5 RPM and 30 RPM, more specifically at 10 RPM, relative to the laser level 12 in the direction 24. As shown, the laser beam 18 rotates in the direction 24 such that at time zero (T0), the laser 18 is emitted along path 26, at time one (T1), the laser beam 18 is emitted along path 28, at time two (T2), the laser beam 18 is emitted along path 30, and at time three (T3), the laser beam 18 is emitted along path 32. In various embodiments, the laser level system 10 allows the conveyance of position information related to the emitted laser points, lines, planes, etc. and the detector panel 22. In various particular embodiments, the laser level system 10 uses the speed at which the laser level 12 moves and the time it takes for the laser beam 18 to pass through the detector 14 to calculate the distance between the laser level 12 and the detector 14. In other embodiments, the laser level system 10 uses the speed at which the laser level 12 moves and the number of pulses of the laser beam 18 that pass through the detector 14 to calculate the distance between the laser level 12 and the detector 14. These determinations can be used for various purposes, such as controlling the automatic alignment of the laser level and the detector.

[0026] When the detector 14 detects the laser beam 18, the detector 14 conveys to the laser level 12 that the laser beam 18 has been detected by generating a control signal (such as an electronic signal). As will be discussed in more detail below, the laser level system 10 includes a pairing or communication frequency (see, e.g., 40, 42, 44) to specifically communicate with the paired laser level 12 rather than another laser level that may also be present and / or in use in the working environment.

[0027] Since the detector 14 determines the time required to receive the laser beam 18, and since the time required to communicate the reception of the laser beam 18 from the detector 14 to the laser level 12, the laser level 12 may have continued to rotate the laser beam 18 past the detector panel 22. In the illustrated example, the laser beam 18 has rotated to path 32. When the laser level 12 receives an indication (e.g., a signal) that the detector 14 has detected the laser beam 18, the laser level 12 rotates the laser beam 18 in the direction 34 opposite to the direction 24 until the laser beam 18 is aligned with the detector panel 22, at which time the detector 14 signals the laser level 12 to stop rotating the laser beam 18.

[0028] During the alignment process, the laser beam 18 is received at the detector 14 and / or at the detector 16. In various embodiments, the detector 14 and / or the detector 16 is a remote control for the laser level 12. When the laser beam 18 traverses the detector panel 22, the detector panel 22 of the detector 14 (e.g., a photodiode array) detects the laser beam 18. In various embodiments, the detector 14 generates a signal, such as an electrical signal, based on the detected laser beam 18. The detector 14 analyzes the signal to improve communication between the detector 14 and the laser level 12. For example, the distance between the laser level 12 and the detector 14 can be calculated, allowing the microcontroller unit (MCU) to determine whether gain or amplification (e.g., the longer the distance, the higher the gain) is required for the signal from the detector 14 to obtain the most accurate reading of the signal.

[0029] Reference Figure 5 , a schematic diagram of the detector 14 according to an exemplary embodiment is shown. As will be generally understood, in a workplace and / or in a working environment, there may be more than one laser level and / or laser level system operating simultaneously. In a working environment using more than one laser level, the detector 14 may detect a laser beam 36 from an unpaired laser level rather than the target laser level 12 during the automatic alignment process. The laser level system 10 pairs and / or allows target communication between the detector 14 and the laser level 12 such that the detector 14 will ignore and / or not recognize unpaired laser levels that are also operating in the environment.

[0030] When the laser level 12 and the detector 14 are powered on, a pairing or communication frequency is selected. In a particular embodiment, the laser level 12 receives a signal from the detector 14 and instructs and / or encodes the diode to emit the selected laser beam frequency. The detector 14 includes a processor configured to compare the frequency of the incident planar beam with the selected pairing frequency. The detector 14 and specifically the processor determine whether the incident laser beam matches the selected pairing frequency, and if the incident laser beam matches the selected pairing frequency, the detector 14 communicates with the laser level 12 by sending a control signal. If the processor of the detector 14 determines that the frequency of the incident laser beam is different from the pairing frequency (i.e., does not match), the detector does not generate a control signal or send a control signal to the laser level emitting the laser beam.

[0031] Reference Figure 6 , a graphical display of multiple pairing frequencies used by the detector 14 and the laser level 12 is shown according to an exemplary embodiment. The laser level system 10 includes a communication system 38 that includes one or more pairing frequencies 40, 42, 44 to allow targeted communication specifically with the laser level 12 (i.e., the paired laser level) rather than another laser level emitting the laser beam 36. In a particular embodiment, the laser level system 10 has three pairing frequencies, including a first pairing frequency 40, a second pairing frequency 42, and a third pairing frequency 44. In other words, in various particular embodiments, the communication system 38 includes a set of pairing frequencies that includes three pairing frequencies. In various particular embodiments, the laser level system 10 includes different numbers of pairing frequencies (2, 4, 5, 6, etc.).

[0032] Each of the one or more pairing frequencies 40, 42, 44 corresponds to a specific laser frequency. As will be generally understood, the laser frequency is the frequency at which the laser beam 18 signal repeats itself with a given amplitude over a period of time. The laser level 12 emits the laser beam 18 at a certain pulse width modulation (PWM) frequency. The PWM frequency can be adjusted by changing various parameters (i.e., pulse repetition rate, duty cycle, etc.).

[0033] 1. In a particular embodiment, when there are three pairing frequencies, the first pairing frequency 40 is a laser frequency of approximately 9.5 kHz (i.e., 9.5 kHz ±.25 kHz), the second pairing frequency 42 is a laser frequency of approximately 10 kHz (i.e., 10 kHz ±.25 kHz), and the third pairing frequency 44 is a laser frequency of approximately 10.5 kHz (i.e., 10.5 kHz ±.25 kHz). In other words, in an embodiment having three pairing frequencies, the three pairing frequencies include a laser frequency of approximately 9.5 kHz, a laser frequency of approximately 10 kHz, and a laser frequency of approximately 10.5 kHz.

[0034] In a specific embodiment, the detector 14 and the laser level 12 communicate using Bluetooth. In particular, once the detector 14 identifies the selected pairing frequencies 40, 42, 44, the detector 14 uses Bluetooth to send a control signal to the laser level 12. In other embodiments, the detector 14 and the laser level 12 communicate in different ways (i.e., WLAN, RF, infrared, etc.).

[0035] Reference Figure 7 , a flowchart showing the automatic alignment process 50 of the laser level system 10 according to an exemplary embodiment is shown. In the first step 52 of the automatic alignment process 50, the user turns on the laser level 12 and the detector 14. In the second step 54 of the automatic alignment process 50, the laser level 12 and the detector 14 select one of the pairing frequencies 40, 42, 44 to use during the alignment process 50. In a specific embodiment, the pairing frequencies 40, 42, 44 are randomly selected from a plurality of pairing frequencies 40, 42, 44. The selection of the pairing frequencies 40, 42, 44 will occur each time the user starts the automatic alignment process 50. In other words, when the user starts another alignment process, the detector 14 and the laser level 12 are configured to select the pairing frequencies. In a specific embodiment, the alignment process 50 is started by actuating a button (such as a pairing button).

[0036] In the third step 56, the laser level 12 will change the diode based on the received signal from the detector 14 and emit the laser beam 18 at the frequency of the selected pairing frequency 40, 42, 44. In the fourth step 58 and the fifth step 60, the detector 14 determines whether the laser beam incident on or passing through the detector 14 has a frequency that matches the pairing frequency. As shown in the fourth step 58, when the laser beam 18 passes through the detector 14 and / or the detector panel 22, the detector 14 identifies the laser beam 18 because it has a frequency that matches the selected pairing frequency 40, 42, 44, and thus continues the automatic alignment process 50. As described above, control signals (e.g., information about position, etc.) are communicated between the detector 14 and the laser level 12, and the process continues until the laser beam 18 has reached the desired alignment position. Once the target alignment is achieved, the detector 14 signals the laser level 12 to stop rotating the laser beam 18.

[0037] As shown in the fifth step 60, in the case where the unpaired laser level emits a laser beam (such as laser beam 36) of another frequency (i.e., a frequency different from the selected pairing frequency), the detector 14 will determine that the frequency of the laser beam 36 is not at the pairing frequency and then ignore and / or not respond to the laser level that emits the laser beam 36. In other words, once the detector 14 determines that the laser beam does not have a pairing frequency, the detector does not send a control signal to the laser level. In this embodiment, the detector 14 continues the automatic alignment process 50 with the paired laser level 12 and sends a control signal until the laser beam 18 reaches the desired alignment position.

[0038] Reference Figure 8 , a method 100 for operating a laser level system 10 according to an exemplary embodiment is shown. In a first step 102 of operating the laser level system 10, the laser level 12 and the detector 14 are provided and positioned by a user in a work environment. In a second step 104, the laser level 12 and the detector 14 are powered on by the user to start the automatic alignment process 50.

[0039] In a third step 106, the laser level 12 and the detector 14 select the pairing frequencies 40, 42, 44 of the laser level 12. In a fourth step 108, the laser level 12 will emit a laser beam 18 at the selected laser frequency that matches the selected pairing frequencies 40, 42, 44.

[0040] In a fifth step 110, the laser level 12 will rotate at the selected speed and cause the laser beam 18 to sweep across or pass by the detector 14. In a sixth step 112, the detector 14 and specifically the processor will determine the laser beam 18 having a laser frequency that matches the selected pairing frequencies 40, 42, 44 and then send a control signal in response, and / or determine that the laser frequency does not match the selected pairing frequency and not send a control signal to the laser level (i.e., ignore the laser beam 36 having a frequency that does not match the selected pairing frequency). In a seventh step 114, after the detector 14 has determined that the laser beam 18 matches the selected pairing frequencies 40, 42, 44, the detector 14 conveys (i.e., sends a control signal) to the laser level 12 that the laser beam 18 has been received and continues the automatic alignment process 50 with the paired laser beam 18 until the laser beam 18 has reached the desired alignment position.

[0041] It should be understood that the drawings show in detail an exemplary embodiment, and it should be understood that the present application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terms are for descriptive purposes only and should not be considered restrictive.

[0042] According to this specification, additional modifications and alternative embodiments of various aspects of this disclosure will be apparent to those skilled in the art. Accordingly, this specification should be construed as merely illustrative. The structures and arrangements shown in the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, many modifications can be made (e.g., changes in the size, dimensions, structure, shape and proportion of various elements, parameter values, installation arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed can be constructed of multiple parts or elements, the positions of the elements can be reversed or otherwise changed, and the nature or number or position of discrete elements can be altered or changed. According to alternative embodiments, the order or sequence of any process, logical algorithm or method step can be changed or re-ordered. Other substitutions, modifications, changes and omissions can also be made in the design, operating conditions and arrangements of the various exemplary embodiments without departing from the scope of this disclosure.

[0043] Unless otherwise expressly stated, no method set forth herein is intended to be construed as requiring that its steps be performed in a particular order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or where no particular order is specifically recited in the claims or the specification, no particular order should be inferred. Additionally, as used herein, the article "a" is intended to include one or more components or elements and is not to be construed as meaning only one.

[0044] For the purposes of this disclosure, the term "coupled" means that two components are directly or indirectly coupled to each other. Such coupling can be fixed in nature or movable in nature. Such coupling can be achieved by integrally forming two members and any additional intermediate members into a single unitary body with each other, or by attaching two members or two members and any additional members to each other. Such coupling can be permanent in nature or alternatively removable or releasable in nature. As used herein, "rigidly coupled" means that two components are coupled in such a way that the components move together in a fixed positional relationship under the action of a force.

[0045] Although the present application recites a particular combination of features in the appended claims, the various different embodiments of the present invention relate to any combination of any of the features described herein (whether such combination is currently claimed or not), and any such combination of features can be claimed in this application or in a future application. Any feature, element or component of any of the above-discussed exemplary embodiments can be used alone or in combination with any feature, element or component of any of the other above-discussed embodiments.

Claims

1. A laser level system, the laser level system comprising: a detector comprising a laser sensor; a laser level configured to emit a planar laser beam and to rotate relative to the detector such that the planar laser beam traverses the detector; Characterized in that the detector and the laser level are configured to select a first pairing frequency from a set of pairing frequencies; wherein, when the planar laser beam is incident on the laser sensor, the detector determines the frequency of the incident planar laser beam and compares the frequency with the first paired frequency; and Wherein, when the detector determines that the incident planar laser beam is at the same frequency as the first paired frequency, the detector identifies the laser level, and the detector generates a control signal based on the planar laser beam.

2. The laser level system according to claim 1, characterized in that When the detector determines that the frequency of the incident planar laser beam is different from the first paired frequency, the detector does not identify the laser level, and the detector does not generate the control signal based on the planar laser beam.

3. The laser level system according to claim 1, characterized in that The planar laser beam is a vertically oriented planar laser beam.

4. The laser level system according to claim 3, characterized in that The laser level is configured to rotate so that the emitted vertically oriented planar laser beam is swept horizontally across the detector such that the vertically oriented planar laser beam traverses the laser sensor detector.

5. The laser level system according to claim 1, characterized in that: The set of pairing frequencies includes three pairing frequencies.

6. The laser level system according to claim 5, characterized in that The first pairing frequency is randomly selected from the three pairing frequencies.

7. The laser level system according to claim 5, characterized in that The three paired frequencies include a laser frequency of 9.5 kHz, a laser frequency of 10 kHz, and a laser frequency of 10.5 kHz.

8. The laser level system according to claim 1, characterized in that: The control signal generated by the detector is an electronic signal.

9. A laser level alignment system, the laser level alignment system comprising: A detector, the detector comprising: Detector panel; a laser level configured to emit a laser beam and to rotate relative to the detector such that the laser beam traverses the detector; Characterized in that the detector and the laser level are configured to select a first pairing frequency; wherein, when the laser beam is incident on the detector panel, the detector determines the frequency of the incident laser beam and compares the frequency with the first paired frequency; wherein when the detector determines that the incident laser beam is at the same frequency as the first paired frequency, the detector identifies the laser level, and the detector generates a control signal based on the laser beam; and Wherein, when the detector determines that the frequency of the incident laser beam is different from the first paired frequency, the detector does not identify the laser level, and the detector does not generate the control signal.

10. The laser level alignment system according to claim 9, characterized in that: When the laser receives a signal that the detector has detected the laser beam, the laser level rotates the laser beam until the laser beam is aligned with the detector.

11. The laser level alignment system according to claim 10, characterized in that: When the laser beam is aligned with the detector, the detector signals the laser level to stop rotating the laser beam.

12. The laser level alignment system according to claim 9, characterized in that: The first pairing frequency is a pulse width modulation frequency.

13. The laser level alignment system according to claim 9, characterized in that: The detector and the laser level communicate via Bluetooth.

14. The laser level alignment system according to claim 9, characterized in that: The laser beam emitted by the laser level is a vertically oriented planar laser beam, and wherein the laser level is configured to rotate so that the emitted vertically oriented planar laser beam is horizontally swept across the detector such that the vertically oriented planar laser beam traverses the detector.

15. The laser level alignment system according to claim 9, characterized in that: The detector panel includes an array of photodiodes.

16. The laser level alignment system of claim 9, wherein: When the user initiates another alignment process, the detector and the laser level are configured to select a second pairing frequency.

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