Laser level system

The present disclosure relates to a laser level system. The laser level system includes a mount, a laser secured to the mount and a remove input device. The mount includes a rotating portion to which the laser level is secured. The remote input device controls rotation of the rotating portion. The laser level is secured to the rotating portion of the mount such that when the rotating portion rotates, the laser level rotates concurrently along with the rotating portion of the mount.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates to a laser level system.

2. Description of Related Art

Laser level systems are well known. Laser levels may be attached to mounting brackets so as to orient the level in a predetermined position relative to an object to which the mounting bracket is mounted.

SUMMARY OF EMBODIMENTS OF THE INVENTION

One aspect of the present disclosure relates to a laser level system. According to one aspect there is an exemplary embodiment of a laser level system that includes a mount, a laser level secured to the mount and a remote input device. The mount includes a rotating portion to which the laser level is secured. The remote input device is configured to control rotation of the rotating portion. The laser level is secured to the rotating portion of the mount such that when the rotating portion rotates, the laser level rotates concurrently along with the rotating portion of the mount.

The mount may further include a motor which effects the rotation of the rotating portion.

The mount may further include a wireless receiver which is configured to receive a signal from the remote input device.

The mount may further include a base and an attachment portion, the attachment portion being transverse to the base.

The attachment portion may include attachment elements configured to connect to a workpiece.

The attachment elements may include magnets.

The rotating portion of the mount may be disposed on the base of the mount.

The motor may be disposed in the base.

The laser level may be a cross-line laser level.

The laser level system may further include a manual adjustment actuator, which is configured to allow a user to manually rotate the rotating portion of the mount.

The mount may include comprising a base and an attachment portion, the base being generally transverse to the attachment portion.

According to another aspect, there is an exemplary embodiment of a laser level system. The laser level system includes a laser level, a mount and a remote input device. The laser level system may be secured to the base of the mount, the laser level including a housing and at least one laser generator housed in the housing, the laser generator configured to project a laser beam outside of the housing. The base may include a rotating portion which rotates relative to the rest of the base portion and the attachment portion. The remote input device may be configured to control rotation of the rotating portion.

The laser level may be secured to the rotating portion of the mount such that when the rotating portion rotates, the laser level rotates concurrently along with the rotating portion of the mount.

The mount may further include a motor which effects the rotation of the rotating portion.

The mount may further include a wireless receiver which is configured to receive a signal from the remote input device.

The mount may further include a base and an attachment portion, the attachment portion being transverse to the base.

The attachment portion may include attachment elements configured to connect to a workpiece.

The laser level system may further include an output shaft connected to and driven by the motor.

The laser level system may further include a first gear connected to and rotatable with the output shaft.

The laser level system may further include a second gear engaged with the first great and configured to rotate with the first gear.

The laser level system may further include a driving shaft, the driving shaft holding the second gear and configured to rotate with the second gear.

There may be third gear on the driving shaft, the third gear operatively connected with the rotating portion to translate the motion of the motor to drive the rotating portion of the mount.

According to another aspect, there is an exemplary embodiment of a laser level system, the system including a mount, a laser level secured to the base of the mount, and a remote input device. The laser level includes a housing and at least one laser generator housed in the housing, the laser generator configured to project a laser beam outside of the housing.

The mount includes a movable portion and a stationary portion, the movable portion being movable relative to the stationary portion.

The mount further comprises a motor configured to selectively drive the movable portion so as to move the movable portion relative to the stationary portion.

The remote input device may include a wireless transmitter.

The mount may include a wireless receiver.

The remote input device may be configured to, in response to a user input, send a wireless signal to the mount in order to actuate the motor to move the movable portion.

The mount may further include at least one gear disposed operatively between the motor and the movable portion, the at least one gear transferring motion from the motor to the movable portion.

The laser may be a cross-line laser level.

The mount may further include a controller.

According to another aspect there is an exemplary embodiment of a laser level system that includes a laser level and a remote input device. The laser level includes a housing and at least one laser generator configured to project a beam outside of the housing onto a surface such as a wall. The laser level further includes a motor housed in the housing, the motor is configured to selectively move output of the laser beam in response to a signal from the remote input device.

The laser level may include a wireless transceiver or a wireless receiver which is configured to receive the signal from the remote input device.

The remote input device may be configured to provide a signal to move a laser beam a particular distance or rotate it about a certain angle. For example, the input device may provide a signal to rotate the laser beam 5 degrees, 10 degrees, 15 degrees, or throughout that range. The remote input device may also provide a signal to move the laser beam 5 mm, 10 mm, 15 mm or various distances throughout that range.

The laser level may be a cross-line laser level.

The laser level may include one or more dot projections.

According to another aspect, there is an exemplary embodiment of a method of determining alignment of a laser level system. The method includes mounting a laser level on a mount, projecting a laser line from the laser level, detecting the laser line with a remote detector, rotating the laser level relative to the mount while keeping the remote detector stationary and determining whether the laser line moves relative to the remote detector as the laser level rotates.

The method may further include indicating that the laser line has moved relative to the remote detector more than a threshold amount.

The laser line may be a substantially horizontal laser line.

The method may further include determining whether the laser line moves relative to the remote detector as the laser level rotates comprises determining whether the laser line moves vertically relative to the remote detector.

The remote detector may further include a photo diode.

The remote detector may further include a window which allows the laser line to project onto the photo diode when the laser line is aligned with the window.

The remote detector may further serve as a remote control device which is configured to control at least one operation of the laser level or the mount.

The remote detector may be configured to control rotation of the laser level relative to the mount.

The remote detector may include a display.

The remote detector may include a controller and a transceiver.

According to another aspect, there is an exemplary embodiment of a method of determining alignment of a laser level, the method including projecting a substantially horizontal laser line from the laser level, detecting the laser line with a remote detector, rotating the laser line while keeping the remote detector stationary and determining a change in a vertical positioning of the laser line relative to the remote detector as the laser line rotates.

The method may further include indicating whether the vertical position has changed more than a threshold amount.

The remote detector may further include a photo diode.

The remote detector may further include a window which allows the laser line to project onto the photo diode when the laser line is aligned with the window.

The remote detector may further serve as a remote control device which is configured to control at least one operation of the laser level or the mount.

The remote detector may be configured to control rotation of the laser level relative to the mount.

The remote detector may include a controller.

According to another aspect, there is an exemplary embodiment of a laser level system, the system includes a mount. A laser level is rotatably secured to the mount and projects a laser line. The system further includes a remote detector. The remote detector includes a photo detector configured to detect the laser line. The remote detector is configured to determine a misalignment of the laser line.

The remote detector may be configured to control rotation of the laser level relative to the mount.

The laser level may include a controller and a transceiver.

The laser level may include an accelerometer.

The accelerometer may determine whether the laser level is in a self-leveling range.

The laser level may transmit to the remote detector the determination of whether the laser level is in a self leveling range.

The laser level may rotate relative to the mount about a rotational axis.

The laser level may include a motor and a battery pack.

The motor may drive a gear.

The gear may contact complementary gearing on the mount and cause the laser level to rotate relative to the mount.

The laser level may include a power tool battery pack which powers the motor.

All closed-ended (e.g., between A and B) and open-ended (greater than C) ranges of values disclosed herein explicitly include all ranges that fall within or nest within such ranges. For example, a disclosed range of 1-10 is understood as also disclosing, among other ranged, 2-10, 1-9, 3-9, etc.

FIG. 1illustrates a laser level system10. Laser level system10includes a laser level12, a laser mount20and a remote input device130. The remote input device130may be a dedicated remote control or may be a computing device such as a personal computer, smartphone or tablet. The remote input device130has an internal transceiver131which is capable of sending and receiving wireless signals. The remote input device130may also include a controller, such as a microprocessor132. The remote input device130may also include a display133which may display images or indicators.

The remote input device130may transmit the wireless signal by any of a variety of means, including via a Bluetooth® protocol, Wi-Fi, an infrared signal or other known means.

As shown inFIGS. 1 and 2, the mount20includes a base portion21and an attachment portion22. The attachment portion22is generally transverse to the base portion21. The attachment portion22includes a pair of magnets23. The magnets23are attracted to various metal surfaces and when they contact such a surface hold the mount20in place. For example, the magnets23may be secured to a metal door hinge or a metal cabinet to secure the mount to the door hinge or cabinet, as the case may be. In other exemplary embodiments, the attachment portion22may include other attachment features instead of or in addition to magnets. For example, the attachment portion22may include straps for securing the mount20to a pole.

As also shown inFIGS. 1 and 2, the base portion21includes a rotating portion25. The rotating portion25of the exemplary embodiment is cylindrical and the laser level12is mounted to the rotating portion25. The rotating portion25rotates about a central axis relative to the remainder of the mount20. This allows the laser level12to rotate and the beams projected by the laser level12to rotate and shine on different surfaces or different parts of a surface.

As shown inFIGS. 1 and 2, the laser level12is a cross-line laser level. The cross-line laser level12includes a housing13and a window14. Internal to the housing13, the laser level12includes a pair of laser generators, which may be laser diodes. The laser diodes project orthogonal beams50,52which may project orthogonal lines54,56on a surface such as a wall. The laser level12may operate similarly to that shown in U.S. Patent Application Publication No. 2014/0352161, which is hereby incorporated by reference in its entirety.

A top perspective view of the base portion21of the mount20is shown inFIG. 3. A portion of the top of the base portion21is shown removed (indicated by dashed lines) so that internal components can be illustrated.

As shown inFIG. 3, the rotating portion25is generally cylindrical. It includes a threaded connector27at its center. The threaded connector27may be connected to a complementary threaded connector on a bottom portion of the housing13of the laser level12in order to secure the laser level12to the rotating portion25of the base portion21. In other embodiments the laser level12can be connected to the rotating portion25by other means. For example, the laser level12may simply be placed on the rotating portion25. In other embodiments, the laser level12could be snapped on the rotating portion25(one or both of the laser level12and the rotating portion25would contain complementary snapping portions).

As shown inFIG. 3, the base portion21houses a battery55. The battery is connected to and provides power to printed circuit board60and motor70. The printed circuit board60may include a controller, such as a microprocessor61, and may also include a wireless transceiver62which serves as both a wireless receiver and wireless transmitter. In other embodiments, there may be only be a receiver or transmitter instead of a transceiver. In some embodiments, there may also be a separate memory. The microprocessor61may include a memory itself.

In use, a signal from the remote controlling device30may be received by the transceiver62. In accordance with the received signal, the microprocessor61can control a flow of electricity from the battery55to the motor70in order to drive the motor70. The motor70has an output shaft71and there is a gear72at an end of the output shaft71. The gear72is cylindrical and has gear teeth73on its circumference. The gear72meshes with another gear74with gear teeth75to transfer motion from the gear72to the gear74. Gear74is connected to a shaft76and the shaft76rotates as the gear74rotates. The shaft is supported at a far end by a bearing77and another gear78is disposed on the shaft76between the bearing77and the gear74. Gear78includes gear teeth79, which mesh with teeth80on a bottom surface of the rotating portion25so as to drive rotation of the rotating portion25. In this manner, rotation of the rotating portion25can be effected by the remote input device130. The battery55, printed circuit board60, microprocessor61, wireless transceiver62, motor70, shaft71, gear72with gear teeth73, gear74with gear teeth75, shaft76, gear78and bearing79are housed internally in the base portion21of the mount20. The remote input device130can send a signal for clockwise or counter-clockwise rotation. The microprocessor61then controls rotation of the motor in the appropriate direction to rotate the rotating portion25in the appropriate direction. Particular inputs for speed of rotation or distance of rotation may also be input into the remote input device130. In a similar manner, the transceiver131transmits the appropriate signal, the signal is received by the transceiver62, and the microprocessor61controls the motor70and battery55in the manner prescribed by the signal of the remote input device130.

Various types of appropriate gears may be used to transfer the motion. For example, the gear78could be a bevel gear and teeth80could serve as corresponding bevel gear teeth on the rotation portion. Elements78and80could also be formed as miter gears or worm gears, with the gear teeth being formed appropriately to transfer motion from the gear78to the rotating portion25.

A user may input commands into the remote input device130through the display133, which may be a touch screen. The user may also use one or more buttons134. For example, the user may input a command through the remote input device130to rotate the rotating portion25of the mount205 degrees counter-clockwise. The user may input a command to rotate the rotating portion at a speed of 5 degrees per second in the counter-clockwise direction. Any of a variety of different speeds, angles and directions may be input.

As additionally shown inFIG. 3, the mount20may include a manual adjust dial95. The manual adjust dial95is connected to the shaft76and may be manually turned to turn the shaft76, and thus the rotating portion. The manual adjust dial95is outside the housing of the mount20so as to be accessible to the user.

FIG. 4. is a bottom perspective view of the rotating portion25. The teeth80discussed above, which mesh with the gear teeth79to drive rotation of the rotating portion25are shown. As additionally seen inFIG. 4, the rotating portion25has a bearing pot91which holds a bearing90, and there is a shaft92. The shaft92is connected to the housing portion of the base21. The rotating portion25can rotate relative to the bearing90which is held stationary by the shaft92.

In other embodiments, there may be a transmission connected to the motor70in order to slow down or speed up the output from the motor70. Additionally, the battery55may be placed in different locations. Furthermore, other types of laser levels may be used than a cross-line laser level. For example, a three line laser level may be used such as that shown in U.S. Patent Application Publication No. 2018/0321035, which is hereby incorporated by reference, in its entirety.

FIGS. 5 and 6illustrate the laser level12with internals and schematically. As shown inFIG. 5, the laser level12includes a laser projection device24, a self-leveling mechanism26, controller22, a housing13a power source40, and/or other components. The laser level12may also include an accelerometer63and wireless transceiver64, each of which are connected to the controller22. The accelerometer63can measure the distance that the laser level12rotates. That can be useful when a user inputs a command to rotate 5 degrees. The motor60itself may be made to move sufficient to produce a 5 degree movement and the accelerometer63may check this movement to ensure 5 degrees is actually achieved. If the accelerometer63information indicates that the 5 degrees has not been achieved, this can be relayed to the remote input device130, and the remote input device130can provide a signal to actuate the motor necessary to correct the rotation. Information from the accelerometer may also be shared with the remote input device130to be displayed on the display133of the device130.

Laser projection device24is configured to generate and/or project a laser beam outwardly from housing20. Laser projection device24includes one or more laser generators30such as laser diodes, one or more optical components32(e.g., lens(es) and/or mirror(s)), and/or other components.

Laser generator30(e.g., laser diode(s)) is configured to emit a laser beam. In some embodiments, laser projection device24includes a single laser diode30. In some embodiments, laser projection device24includes two or more laser diodes. Laser generator30may produce visible light having a predetermined wavelength (e.g., in the range of 400-700 nm). Laser generator30may produce a red laser beam, a green laser beam, and/or laser beams of other colors and/or wavelengths. In some embodiments, laser generator30may have a predetermined output power and/or input voltage. For example, the output power may be between about 0.5 and 20 mW. The input voltage may be between about 2.7 volts and about 7.0 volts.

In some embodiments, the laser beam(s) projected out of housing20comprise one or more point-source beams that generate points on the objects they hit. Such point-source beams may be oriented orthogonally to each other (e.g., beam(s) projecting in any of four orthogonal horizontal directions, a beam projecting vertically upwardly, and/or a beam projecting vertically downwardly).

In some embodiments, the laser beam(s) are converted into fan beams (e.g., planar beams/light planes) via optical components32so as to project light lines onto the objects they intersect. Optical components32may include lenses, collimators (e.g., collimating lenses, collimating tube), apertures, and/or other optical components. Optical components32may include cylindrical lenses32aand/or non-cylindrical lenses. In some embodiments, for example as shown inFIG. 1, one or more optical components32may include orthogonally oriented rod/cylinder lenses32athat convert a point-source (i.e., linear) beam from a single diode30into two orthogonal planar (e.g., fan-shaped) beams that project a cross shape (e.g., a “+” shape) onto an object such as a wall. The point-source beam from the diode30is collimated and then generally directed to an intersection between the two cylinder lenses32a, without previously being split. The portions of the point-source/linear beam that impinge upon the respective lenses32aare converted into respective orthogonal fan-shaped planar beams50,52, as shown inFIG. 1. Alternatively, discrete laser generators30may be used for each planar beam (e.g., as shown in U.S. Pat. No. 6,763,595, the contents of which are hereby incorporated herein by reference). The output beams may comprise two, three, or more orthogonal planar beams. Such point-source and planar beam generating laser levels are well known in the art (e.g., as shown in U.S. Pat. Nos. 6,763,595; 6,763,596; 5,539,990; which are herein incorporated by reference, in their entirety).

Self-leveling mechanism26is supported by housing13and configured to orient the laser beam(s) in a predetermined direction relative to gravity. Self-leveling mechanism26may comprise any suitable self-leveling mechanism known in the art (e.g., a pendulum26bthat pendulously supports the laser generator(s)30(e.g., laser diode(s)) and/or one or more of the optical components32, a motorized self-leveling mechanism that senses levelness and responsively tilts a portion of the level). In the embodiment illustrated inFIG. 7, self-leveling mechanism26comprises a pendulum26bthat is mounted to housing13and supports laser projection device24(including laser generator(s)30and optical components32) so as to pendulously support laser projection device24from housing13. As shown inFIG. 6, self-leveling mechanism26may suspend the pendulum26b(including components of laser projection device24supported by the pendulum26b) from housing13by a gimbal26aand/or other pendulous connection that extends between the housing13and pendulum26b. In some embodiments, for example as shown inFIG. 7, the pendulum26bholds laser generator(s)30, at least one of one or more optical components32, and/or other components. Self-leveling mechanism26is configured to orient laser generator(s)30and/or one or more optical components32such that the one or more laser light planes are projected at predetermined angles relative to gravity (e.g., horizontally and vertically). Housing13is configured to contain laser projection device24and self-leveling mechanism26such that at least a portion of laser projection device24moves pendulously within housing13responsive to housing13being tilted by a user. In some embodiments, self-leveling mechanism26may include a magnetic damper29. Such self-leveling mechanisms are well-known in the art (e.g., as shown in U.S. Pat. Nos. 6,763,595; 6,763,596; 5,539,990).

By way of a non-limiting example,FIG. 1illustrates laser level12projecting two substantially perpendicular laser light planes50,52. Projected laser light planes50and52form illuminated lines54and56on a target surface (e.g., a nearby wall).

In another exemplary embodiment, the motor70and gearing components may be internal to or integrated with the laser level12, rather than be part of the mount. In that instance, the mount would not include the rotating portion25. Rather, it would have a stationary base. It may still include the threaded connector27so that the laser level12can connect to the mount.FIG. 7illustrates this exemplary embodiment. Like parts are numbered and operate similarly to the above.

FIG. 7illustrates a motor and gear system in the housing13of the laser level12. The housing13is shown only in parts. As shown, the shafts76and71are supported in ends of the housing13. The remaining components that were housed in the base21in the previous embodiment are likewise housed in the laser level housing13. The gear78is configured to engage a surface of the magnetic damper29. The magnetic damper29may be provided with teeth80such that the gear78can rotationally drive the laser level assembly through the magnetic damper29. In other instances, the gear78may instead be a frictional member, such as a rubber ring. The frictional member can engage the magnetic damper which may, or may not, have a corresponding frictional member. The frictional member on the shaft76in place of gear78can then drive the rotational motion of the laser level components so as to rotate at least one of the laser beams.

In another embodiment, the motor70may simply directly drive a frictional element. For example, as shown inFIG. 8, the motor60may drive a frictional member101directly on the output shaft71. The frictional member101may then directly engage a part to be rotated. That may include the rotating portion25or the damper29. The motor60and related components would be held in either the laser level housing13if integral with the laser level, or the mount base21if part of the mount20. A direct drive may also be accomplished by using gears instead of a frictional element. In either event, either the frictional member101or a suitable gear transfers motion from the axis of rotation of the motor60along the shaft71to rotate the rotating portion25of damper29selectively in the directions shown. If a frictional member101is used, it may not be necessary to include gearing on the rotation parts (25or29). Also, a frictional member101may be used instead of gearing in the other embodiments, as appropriate.

In yet another exemplary embodiment, the laser level12may include a platform125which provides for rotation of the laser level12. As shown inFIG. 9, the laser level12includes a platform125. The platform has a rotating portion126between the platform125and housing13. The rotating portion126operates similarly to the rotating portion25of the mount20. Additionally, the platform125operates similarly to the base21of the mount and houses similar components, and operation of like components is the same unless otherwise discussed.

As shown inFIG. 10. The platform125has a similar configuration as the base21when it includes a motor70to rotate rotating portion25. In this instance, motor70is configured to drive rotating portion126in a similar manner. Particularly, gear78may mesh with teeth80(not shown) of the rotating portion126to rotate the rotating portion, and thus the laser beams from the laser level12. In this instance, the rotating portion126may be fixed to the laser level housing13and the platform125.

As will be appreciated, various features of the embodiments may be combined or replaced with features from the other embodiments. In each of the embodiments, the remote input device130may be used to control rotation of the laser level12or a portion of the laser level.

FIG. 11illustrates another exemplary embodiment of a laser level212. Laser level212projects laser lines in three perpendicular planes from three projectors221,222and223to create a three-line laser level. Projector221projects a horizontal beam and projectors222and223each project vertical beams. The laser level212is powered by a removable power tool battery pack320. Three-line laser levels are known in the art, and laser level212is of the same type as that shown in U.S. Patent Application Publication No. 2018/0321035, which is hereby incorporated by reference in its entirety.

FIG. 12is a cut-away view of the laser level212. The cutaway view shows laser modules250for the laser projectors221and222. Each laser module includes a laser diode251that serves as a laser generating source. The laser diode251is held in a barrel253which is generally cylindrical in shape. The laser modules250also include cone member268. Lasers projected by the laser diodes251hit the cone members268and are reflected into lines241and242. Line241is a horizontal line and line251is a vertical line when the laser level212is placed on a horizontal surface, the laser modules250are properly calibrated and they are allowed to settle to their leveled position under gravity. InFIG. 12, the laser modules250are tilted such that they are mis-calibrated. Accordingly, line241is slightly off from horizontal and line251is slightly off from vertical.

The laser level212is connected to a base312. It may be connected with a threaded fastener. The base312may itself be connected to a tripod400, as is shown inFIG. 14. This may be done through threading the base312onto the tripod400, one of the base312and the tripod400having a threaded projection and the other having a threaded hole for receiving a threaded projection.

FIG. 13is a close-up of a section ofFIG. 12. As shown inFIGS. 12 and 13, the laser level212includes a motor321. The motor321may also be powered by the battery pack320. The motor is connected to and drives a fine adjust drive gear322. The fine adjust drive gear322meshes with complementary gearing313on the base312such that when the motor drives the fine adjust drive gear322, the laser level212moves relative to the base312. In particular, the laser level212rotates about a rotational axis314at which it is connected to the base312.

Rotation and other control of the laser level212may be performed by a remote input device, such as the remote input device130previously discussed. As with the other embodiments, the laser level212may have a transceiver configured to receive a signal from the remote input device and a controller132to control operation of the motor and laser diodes.

As mentioned above, the laser modules250inFIG. 12are misaligned. The beam241is not truly horizontal and the beam242is not truly vertical. For example, the laser line241is lower towards a front of the laser level212(left side ofFIG. 12; opposite the battery320) and is higher in the rear. Accordingly, as the laser level212rotates, the line241projected onto a stationary wall moves up and down.

FIG. 12includes a wall500. The beam241will be lower on the wall500when in the position shown inFIG. 12, than when the laser level212is rotate 180 degrees such that the battery is in the front and the higher portion of the beam241hits the wall.

FIGS. 14-17illustrate an exemplary embodiment in which a detector330serves as a remote input device and also provides a calibration feature for the laser level. The detector330has the functionality of the previously described remote input device130and the additional functionality described here. Additionally, while the detector330and calibration feature will be described with respect to laser level212, it similarly could be implemented on the previously described laser levels and systems.

FIG. 14illustrates a tripod400. The base312is mounted to the tripod400and the laser level212is mounted on the base. As previously discussed, the projector221projects a line241. When properly calibrated, and allowed to settle to a leveled position, the line241should be a horizontal beam or near horizontal beam. As shown inFIG. 14, a user410may hold a detector330against a wall500.FIG. 15illustrates a close-up view of the detector330on the wall500. As shown, the detector330is held at the level of the line241.

FIG. 16is an illustration of the detector330. As shown inFIGS. 15 and 16, the detector has a window331for a photo-detector which can detect the presence of the laser line241or another laser output. The photo-detector may be a photo diode/avalanche photo diode. When the laser line241passes through the window331, the photo-detector situated behind the detects the laser line241. On the other hand, when the laser line241is outside of the window331, the laser line does not pass through the window331to the photo-detector.

In a properly calibrated laser level212, when the detector330is held stationary against the wall500such that the laser line241passes through the window331, if the laser level212is rotated with respect to the base312(as discussed above), the laser line241will continue to pass through the window331and be detected by a photo-detector behind the window331.

However, in a misaligned laser level212, the laser line241will move vertically up and down with respect to the detector330and the window331. Accordingly, if the laser line241is initially lined up with the window331so that it is detected by the photo-detector, when the laser level212rotates, the line241will move up or down with respect to the wall500, detector330and window331that allows the laser through to the photo detector. If the line241moves sufficiently, then the laser line241will no longer overlap the window331. In that instance, the laser line241will no longer pass through the window331and no longer be detected by the photo detector.

FIG. 17illustrates the laser line241in a variety of positions with respect to the detector330. Particularly, it shows five positions of the laser line241—A, B, C, D and E. As discussed, as the laser level212rotates, the position of the laser line241may change in the event that the laser level212is misaligned or otherwise malfunctioning. As shown inFIG. 17, when the laser line241is at a position A, the line passes partially through the window331. Accordingly, the laser line241can be picked up by the photo diode. When at positions B and C, the laser line241passes clearly through the window. Therefore, the line241passes through the window331and can be detected by the photo detector. When the laser line241is in the positions D and E, the line241passes below the window331. Accordingly, the laser line241does not pass through the window331, does not reach the photo detector and is therefore not detected by the photo detector. This allows a user410to determine if the laser level212is adequately calibrated.

In order to determine whether the laser level212is adequately calibrated, the user410places the detector330on the wall500with the line241passing through a center of the window331. The center of the window331may be identified by markings335on the detector330.

Once the line241is aligned with the markings335identifying the center of the window331, the user410or another worker may instruct the laser level212to rotate around one time (360 degrees). This may be done through the detector330which serves as a remote control, or by using controls on the laser level212(or the bracket312or tripod400, if applicable). If the laser level212is well aligned, the line241will pass through the window331through the entire 360 degree rotation of the laser level212. In this instance, the photo detector will continuously detect the laser line241and a controller of the detector330can determine that the laser level212is properly aligned because the line241does not move significantly up or down vertically through the rotation. The detector330can then inform a user that the laser level212is properly aligned. The detector330can have a display or indicator that indicates that the laser level212is properly aligned. The indicator may be a simple LED light that is activated when the laser level212is properly aligned. The display may also be a more elaborate display such as an LCD or other screen that displays text or other graphics indicating proper alignment. A similar display or indicator may additionally or alternatively be placed on the laser level212or the base312.

In the event that the laser level212is misaligned, while the line241initially starts off projecting through the window331, the line241will deviate from that position as the laser level212is rotated. For example, with reference toFIG. 17, the detector330may be initially positioned such that the laser line241is at a location B. At location B, the laser line241overlaps with the window331and is detected by a photo-detector. Then, as the laser level212rotates, the laser line241may move to the positions D or E. When the laser line241moves to the D or E positions, the laser line241no longer shines through the window331and is no longer detected by the photo detector behind the window331. Accordingly, the laser line241is no longer detected, and the controller of the detector330can determine that the laser level is misaligned due to the vertical drifting of the laser line241. Similar to when the laser level212is properly aligned, the detector330can have a display or indicator that indicates that the laser level212is not properly aligned (i.e., misaligned). The indicator may be a simple LED light that is activated when the laser level212is misaligned. The display may also be a more elaborate display such as an LCD or other screen that displays text or other graphics indicating proper alignment. A similar display or indicator may additionally or alternatively be placed on the laser level212or the base312.

In the present exemplary embodiment, there is a single window331with a single photo detector behind the window331. The user410initially lines up the line241with a center of the window331, perhaps with the help of a marking335located at the center of the window331.

In other embodiments, there may be multiple photo-detectors behind the window, including a central photo detector, and the detector330may indicate when the line241is lined up on the central photo-detector. For example, there may be three photo-detectors vertically aligned and the detector330may indicate when the laser line241is lined up with the central photo detector. In that event, there may be in some embodiments one window, more than one window or dividers to prevent leakage of the signal to multiple photo detectors.

In the present exemplary embodiment, the height H of the window331may be adjusted in order to adjust the sensitivity of the calibration. If the laser line241is initially located at a center of the window331, movement of roughly half the height H of the window will indicate that the laser level212is misaligned. That is, if the laser line241initially shines through the window331at the center marking335and the window331has a height of H moving roughly ½ H either up or down will cause the laser line to be outside of the window331. Accordingly, the height H of the window helps to determine the sensitivity. If the height H is approximately ¼ inch, movement of greater than ⅛ inch will produce a misalignment reading. If the height H is approximately ½ inch, it will take a movement of approximately ¼ inch or greater to produce a misalignment reading. The window331of the present exemplary embodiment have a height of ¼ inch or less; ⅜ inch or less; ½ inch or less; ⅝ inch or less; ¾ inch or less; ⅞ inch or less; or 1 inch or less.

Additionally, the distance between the laser level212and the wall500may affect the calibration. Accordingly, instructions may provide the user with a reference distance. For example, an instruction manual may indicate that the user should place a front surface of the laser level212ten feet away from the wall500. The user could also be instructed to change the distance depending upon a desired sensitivity. That is, the user could place the laser level212closer to the wall500and detector330if a lower sensitivity is desired (more often considered aligned) and farther away from the wall500if a higher sensitivity is desired (more often determined as misaligned).

FIG. 18illustrates a schematic view of the detector330. As shown in the schematic, the detector330includes the same components as remote input device130and additionally includes the window331and a photo detector332behind the window331.

As stated above, the calibration feature may be included and or combined with the other embodiments described herein.

The laser level212may also include an accelerometer63. The accelerometer63is functionally connected to a controller such as a microcontroller61. The accelerometer63in the laser level212may in addition to the functionality described above, determine if the laser level212is placed on a surface or tripod in a way that the laser level212horizontal. That is, if the laser level212is placed on a flat horizontal surface, or the mount312is placed on a flat horizontal surface, the line241should be horizontal or nearly horizontal if properly calibrated. The surface and positioning of the laser level212does not need to be precisely horizontal, as the laser modules250are on a self-leveling pendulum mount that provides some degree of movement. This pendulum mount allows the modules250to correctly position under gravity for about 10 degrees. Outside of this range, the modules250are unable to self level. Accordingly, the accelerometer63can determine whether the laser level212is outside of the self-leveling range and convey this information to the detector330. The detector330can then display or alert the user410that the laser level212is outside of the self-leveling range. This can be done through an indicator or other display. When the laser level212is outside of the self-leveling range, the line241will generally not be horizontal regardless of the calibration and a detection of alignment cannot be performed.