Laser Line Generator with Orthogonal Intersecting Light Planes
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Solution Overview
Problem
Existing laser line generators lack the capability to efficiently generate intersecting laser plumb beams at right angles for construction layout tasks, particularly in transferring squared lines between floors and ceilings, and do not provide adequate visibility in bright environments or at long distances.
Innovation Solution
A laser line generating device with a gimbal assembly for self-leveling, transparent encased laser modules emitting planes of light with fan angles greater than 180 degrees, and a modulation scheme with a high duty cycle to ensure visibility, along with a calibration technique to correct alignment errors and an inclinometer for tilt detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional laser line generators are used, then basic laser line generation is possible, but the capability to generate intersecting laser plumb beams at right angles is lacking
Solution Approach 1:
The device is divided into three independent laser modules, each generating a separate plane of light. These modules are arranged orthogonally to create three intersecting planes that form laser plumb beams at right angles, enabling versatile construction layout tasks while maintaining modular simplicity
Solution Approach 2:
Three laser modules are combined within a single housing unit with shared power supply and control circuitry. The modules work together to produce multiple intersecting laser planes simultaneously, providing advanced functionality without requiring three separate devices
2Illumination intensity
If laser modules are enclosed in transparent enclosures, then visibility of laser lines is improved, but protection from environmental factors is reduced
Solution Approach 1:
Transparent protective enclosures made of durable material are designed to protect laser modules from dust and physical damage while maintaining optical transparency. The enclosures act as protective barriers that do not compromise laser line visibility, balancing protection with optical performance
3Illumination intensity
If a high duty cycle modulation scheme is used, then visibility in bright environments is improved, but energy consumption increases
Solution Approach 1:
The laser diodes are modulated with a high duty cycle (e.g., 80-95%) rather than continuous operation, creating periodic light emission that enhances visibility in bright environments. The periodic modulation allows brief intervals of reduced energy consumption while maintaining effective visibility during active periods
4Measurement precision
If a gimbal assembly with inclinometer is added for self-leveling, then accuracy of horizontal/vertical alignment is improved, but device complexity increases
Solution Approach 1:
The gimbal assembly with inclinometer enables the device to automatically detect and compensate for tilt angles, achieving self-leveling functionality. The system autonomously adjusts the laser plane orientation based on gravitational reference, eliminating the need for manual leveling operations by users
5Adaptability or versatility
If three laser modules are integrated into a single housing, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The device employs three separate laser modules that can be manufactured and tested independently before final assembly. Each module is a self-contained unit with its own laser diode, optics, and mounting structure, allowing standardized mass production of modular components that are then integrated into the housing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate generation of intersecting laser lines for construction layout, maintains visibility across varying distances and lighting conditions, and simplifies user interface by eliminating mode selection switches.
Implementation Method 1
A laser diode (24) is press fit into the passage 23... The laser diode 24 emits a beam of light upward into the passage 23
Implementation Method 2
A reflective element (36) having a conical reflecting surface (37)... the beam of light is incident upon the conical surface of the reflective element 36. The conical surface in turn reflects the beam of light outward to form a plane of light
Implementation Method 3
The chassis of the laser line generating device 10 preferably is mounted onto a gimbal assembly that supports rotation along two axis
Data Source
Figure 1~3
Figure 2
Figure 4A~4B
AI summary
An improved laser line generating device is provided for use in construction layout tasks. The laser line generating device is comprised of a first laser light generator operable to emit from a housing a first plane of light having a fan angle greater than 180° and arranged in the housing to project the first plane of light perpendicular to a horizontal plane; and a second laser light generator operable to emit from the housing a second plane of light having a fan angle greater than 180° and arranged in the housing to project the second plane of light perpendicular to the first plane of light and perpendicular to the horizontal plane, such that the first plane of light intersects with the second plane of light at two points. A third laser light generator is operable to emit a third plane of light having a fan angle greater than 90° from the housing and arranged in the housing to project the third plane of light perpendicular to the first and the second plane of light, such that the third plane of light intersects with both the first and second planes of light.