Portable Laser Calibration Rig for Uneven Architectural Surfaces
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Solution Overview
Problem
Construction templates for building constructions are labor-intensive, time-consuming, and inaccurate, leading to misplacement of materials and increased costs due to the need for single-use templates and additional labor to correct errors.
Innovation Solution
A portable and reusable calibration system using a calibration rig with flexible or rigid components, including reflective calibration locators, that can be easily set up on uneven surfaces to project an accurate architectural layout by comparing actual and predetermined calibration locations using a laser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If construction templates are used to map construction materials, then the layout can be transferred to the building slab, but the process becomes labor-intensive, time-consuming, and expensive due to single-use templates and positioning challenges
Solution Approach 1:
The patent uses a reusable template system with multiple templates that can be repeatedly positioned and used across different locations. Instead of creating new single-use templates for each location, the same templates are copied across the workspace through systematic positioning using reference marks and alignment features, reducing both labor and time
Solution Approach 2:
The patent establishes a reference framework beforehand by creating reference marks on the building slab and designing templates with pre-integrated alignment features. This preliminary setup enables rapid subsequent template placements without requiring time-consuming measurements and positioning for each individual template
2Measurement precision
If construction templates are adhered to the building slab, then the layout can be transferred, but vertical objects interfere with template placement and the process becomes challenging
Solution Approach 1:
The patent divides the construction area into multiple zones using a grid system of reference marks. Templates are designed to cover specific grid sections, allowing placement to proceed systematically around vertical obstacles. The segmentation enables work to continue in unaffected areas without being blocked by vertical objects
Solution Approach 2:
The patent introduces reference marks as intermediary elements between the building slab and the templates. These reference marks serve as mediators that facilitate template positioning without requiring direct adhesion to the slab surface in problematic areas, enabling templates to be accurately positioned even when vertical objects interfere with direct placement
3Productivity
If construction templates are positioned manually, then they can be placed on the slab, but accuracy is often insufficient leading to material misplacement and additional correction costs
Solution Approach 1:
The patent incorporates feedback mechanisms through reference marks that provide visual confirmation of correct template positioning. The templates include alignment features that must match the reference marks, providing immediate feedback when the template is correctly positioned. This feedback system ensures high positioning accuracy without requiring complex measurement tools or multiple adjustment iterations
Solution Approach 2:
The patent replaces manual measurement and positioning mechanics with a standardized alignment system. Instead of relying on workers to manually measure and position each template using traditional tools, the system uses pre-configured alignment features and reference marks that guide placement through mechanical fitting, substantially improving positioning accuracy and reducing correction needs
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
The calibration system enables accurate projection of architectural layouts on uneven surfaces, reducing labor and material waste by allowing for quick setup and reusability across multiple sites, ensuring precise placement of construction materials.
Implementation Method 1
The laser scans the plurality of reflective calibration locators positioned at the known points to determine actual calibration locations of the calibration locators
Data Source
AI summary
Apparatuses and methods for accurately applying an architectural layout to a surface. A calibration system includes a calibration rig having a plurality of vertical calibration legs assembled with a plurality of horizontal calibration legs and a laser that emits one or more beams of light onto a work surface to position the architectural layout relative to the calibration rig on the work surface. Calibration markers are positioned at intersections of the vertical and horizontal calibration legs for the laser to scan and confirm calibration accuracy of each of the calibration markers. The calibration markers calibrate the laser by using fixed, known points on the calibration grid that can be folded, collapsed, disassembled, and/or rolled for easy transport to other locations. The work surface can include obstacles and/or be uneven.