1. Field of the Invention
The present invention relates generally to the projection of visible lines and other useful markings onto a surface and, more particularly, to systems employing one or more lasers to project such markings upon a surface.
2. Description of the Related Art
To maximize production output, certain work site activities may take place on a continuous (i.e. “round-the-clock”) basis. Such is the case, in particular, in those activities driven by high capital investment, in which the equipment used is very specialized and acquired at high cost. At a mining site, for example, it is not uncommon for large dump trucks to shuttle back and forth between the same two stations many times over the course of a day, and for these trucks to be operated in shifts so that they are always in use (other than for refueling or maintenance). At one location, a load of ore may be dumped into the bed of the truck. At another, the load is dumped into a crushing pit. This circuit is repeated many times throughout the course of a 24-hour day, by each of a plurality of trucks, with the steady stream of ore being needed to feed a continuous processing operation which, if interrupted, results in lost productivity and in lost profits to the mine operator/owner.
The inventor herein has observed that vehicles approaching a site of the type exemplified above are operated by highly skilled drivers. However, even for such drivers, it is a challenge to properly align the vehicle perfectly, the first time, every time. The risk of damaging adjacent structures or equipment is ever present. While guiding markers could theoretically be used, these are subject to damage and would restrict movement of vehicles and equipment in the vicinity of the discharge station or other facility being approached. Paint applied directly to the surface, on the other hand, would quickly deteriorate and/or be obscured by shifting sand, rocks or dirt.
A need therefore exists for a system and method for providing a visible reference aid to guide vehicles and equipment at an activity site characterized by continuous operation.
A further need exists for a system and method for providing such a reference aid in a manner which is both safe and not susceptible to variations in ambient daylight over the course, for example, of one or more cycles of 24 hour operation.
The aforementioned needs are addressed, and an advance is made in the art, by an apparatus for continuously providing at least one visible line for the duration of a site activity period, wherein the projected visible is usable as a reference aid throughout the site activity period despite dynamically variable ambient lighting conditions. Embodiments of the system include at least one laser source operative to direct optical energy at a wavelength of between 380 nm and 750 nm upon a surface proximate a first site location and an ambient light sensor dimensioned and arranged to detect variations in an intensity of sunlight at the first site location so as to approximate an intensity of sunlight striking the surface. Each laser source includes one or more lasers operated a power level of 10 to 100 W each, and either in tandem such that their output is combined or in a prescribed sequence, so that less than all of a plurality of lasers (i.e., a subset) are operated at any given interval within the site activity period.
A computer, which includes a processor and a memory, is operatively associated with the ambient light sensor, the processor being operative to execute instructions stored in memory to select, responsive to detected changes in ambient light intensity, any of a same, decreased and increased laser power output in order to continuously maintain visibility of a projected line for the duration of the site activity period. A laser controller is operatively associated with the at least one laser and, according to embodiments of the invention, is communicatively coupled to the computer. The laser source controller is operative to modulate an output of the at least one laser source responsive to commands from the computer to any of maintain, decrease or increase an output of the at least one laser source.
A computer implemented method for continuously projecting a reference aid over the course of an activity period is also described. The method comprises receiving, at a computer controlled laser projection system, a request to project at least one line extending from a first site location, over a site activity period, as a reference aid for use in at least one of approaching and departing the first site location. The method further comprises detecting variations in ambient light intensity during the site activity period, and operating at least one laser source of the laser projection system, responsive to the detecting, to project a lane which is visible continuously throughout the site activity period.
According to embodiments, the site activity period is at least 24 hours and the operating is performed continuously over the site activity period and under ambient operating conditions ranging from full daylight to artificial light only. Disruption of operation occurs only if a manual override is actuated, or an unsafe condition such as a dangerous level of explosive vapor in the atmosphere or a level of vibration indicative of an explosion or other even disruptive to continued processing operations at the site location. While the system is in use, vehicles and equipment are operated by reference to the projected line to situate them at a desired location relative to a work site processing facility or other work site location.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limits of the present invention, and wherein:
The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
As used herein, the term “laser source” is intended to refer both to arrangements in which a coherent laser beam source and beam projecting optics are integrated into a single housing at a common mounting location and to arrangements in which the laser source itself consists of optical beam collimating, diffusing and/or scanning elements configured to receive, via a waveguide (e.g., optical fiber), the output of a remotely located laser source. The term “laser sources” should also be understood to encompass other line forming arrangements besides those which rely upon beam diffusing elements such as lenses, including for example, the movement of mirrors to implement a “scanning” operation.
With initial reference to
According to some embodiments, at least one of the sensors is a commercially available ambient light intensity sensor, operating on the principles of devices used by photographers to detect lighting levels during photography sessions. The ambient light sensors are operative to detect variations in the amount of light at the site location over the course of an activity period. While an activity period may vary in duration, and may be interrupted for such reasons as scheduled maintenance, unanticipated equipment failure, or safety reasons, embodiments of the invention are operative to project a visible line for extended periods of time which may range from a few hours to a few days to a few weeks and even to months or years of uninterrupted operation. During night time (artificial light only) operation, a much smaller amount of laser output is required. In full daylight, on the other hand, the full output of several lasers may be required to generate a reference aid bright enough to be seen. Responsive to input provided by ambient light sensors located at each site location, the output of each laser projecting system as system 120 is adjusted so that a visible light is generated at all times. According to some embodiments, such dynamic adjustment comprises selecting one of a plurality of output levels according to whether the detected level of ambient light intensity falls within a range associated with the selected level.
According to some embodiments, projectors 122, 132 and 142 are configured with movable x-y scanning heads so, for example, that the complex lane pattern as patterns 150, 152 and 154 shown at Site Locations A, B and C of
According to some embodiments, projectors 122, 132 and 142 utilize one or more scanning projector and control arrangement of the type disclosed in U.S. Pat. No. 7,219,438 entitled SYSTEM FOR OPERATING ONE OR MORE SUSPENDED LASER PROJECTORS TO PROJECT A TEMPORARY VISIBLE IMAGE ONTO A SURFACE. Closed-loop galvanic scanners (also called “position detecting” scanners), for example, are commonly used in the laser light entertainment industry and are capable of directing a beam to 24,000 to 30,000 discrete points along a selected path every second.
With particular reference now to
As noted previously, a purpose of station 110 is to control the operation of the respective laser projector systems 120, 130 and 140 responsively to inputs received from a plurality of sensors as sensors. Electrical signals representative of the detected sensor values are received at communication 119. According to some embodiments, these signals are wirelessly transmitted by at least some of the sensors, with each sensor having a unique identifier such as a media access control (MAC) address or other means of identifying itself to control station computer 110. An exemplary ambient light intensity sensor 124a associated with Site Location A is shown in
Processor 112 executes instructions stored in memory leading to a comparison between a detected ambient light value and a series of reference ranges stored in datastore 118. According to some embodiments, each reference range represents that range of detected ambient light values at which one or more lasers operated individually or in combination produce a reference aid of sufficient visibility as to be useful to vehicle and equipment operators. According to other embodiments, a set of operating set points corresponding to a performance curve may be fixed by software, wherein this operating curve is used as the reference by which the output of each laser or each laser source is modulated with respect to time. As will be readily appreciated by those skilled in the art, the sensory input is not required during times of artificial lighting (i.e., after sundown and before sunrise) so dynamically variable operation according to a sensory input approach, as exemplified above, is preferably suspended during such times.
According to some embodiments, the processor 112 of control station computer 110 is responsive to input from light intensity sensors as sensor 124a, at Site Location A, to immediately disable the output of the associated laser projection system 120 when a reduction in the intensity of ambient light is so rapid as to cause the pupil of the average human eye to dilate sufficiently to expose that eye to levels of visible laser radiation in excess of the accessible emission limits contained in Table II of 21 CFR Subchapter J Part 1040.10 (i.e., above the threshold for Class IIIa mode of operation under rules promulgated by the U.S. Center for Devices and Radiological Health.
Other types of sensors which may be processed by processor 112 of station 110 include vibration sensors and vapor sensors 124b and 124c, respectively, associated with Site Location A. When a level of vibration indicative of an explosion is detected by sensor 124b, which is predictive of a disruption in operation, an unsafe operating condition, or a strong possibility of system component misalignment, control station computer 110 instructs the laser projection systems affected by the condition to shut off until the issue is resolved. Likewise, vapor sensor 124c is configured to characterize and determine the level of explosive vapors in the atmosphere surrounding a site location as Site Location A (
It will be recalled that in the embodiment depicted in
With continued reference to
Multiple projectors as shown in
An exemplary projector useful, yet simple, reference aids according to embodiments is disclosed in
In any event, and with continued reference to
It will, of course, be readily appreciated by those skilled in the art that a variety of other projection module mounting configurations are possible besides those exemplified by
For a line width of approximately 4″ inches, excellent results in full daylight ambient lighting conditions have been achieved using two lasers each operated at 50 W. Suitable lasers include frequency doubled, Q-switched Nd:YAG laser adapted to generate laser pulses at a wavelength of 532 nm. Emission at this wavelength is especially preferred since it is very close to the peak (555 nm) of the human eye's sensitivity. By comparison, in an argon ion laser operating in continuous wave (cw) mode, roughly half of the output is at 514 nm (58% as bright as the same beam at 555 nm), another 30% is at around 480 nm (18% as bright) and the remaining 20% is at around 440 nm (barely visible to the human eye). Thus, an argon laser would theoretically have to deliver up to three or four times as much power to match the visibility of the Nd:YAG laser.
With simultaneous reference now to
At block 506, the method energizes one or more laser sources are energized (as lasers A1 to An of
Turning now to
The process of block 508 proceeds to block 510, which includes sub process block 606, wherein an initial light intensity measurement is received and processed. According to some embodiments, a light intensity sensor may be present at each activity site location. Alternatively, a single light intensity sensor may be used. The measured value(s) is/are stored in the memory of the control station computer and, according to some embodiments, the computer processor selects an initial laser output power requirement based on the measurement(s).
In some embodiments, a respective, satisfactory power level is stored for a corresponding range of measured values. If the measurement(s) fall within one of these ranges, the applicable power level is selected for the laser(s) associated with at least the activity site location at which the sensor measurement was acquired. At sub-block 608 of block 510, as new ambient light intensity measurements are acquired, they are compared as described above to determine whether they are still within the range determined for the preceding interval. If so, the process returns to block 514 (
With reference now to
Returning to block 700, it should be noted that if a level of explosive vapor is detected which is above the upper explosive limit, this too may be processed by control station computer 110 or 310 (
With final reference now to
Continuing with the example of
While given components of the system have been described separately, one of ordinary skill also will appreciate that some of the functions may be combined or shared in given instructions, program sequences, code portions, and the like. The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.