Patent Description:
The invention seeks to provide improved laser tools, and an improved laser tool system, in terms of functionality, versatility and ease of use, for example.

<CIT> discloses a laser level for projecting horizontal and vertical laser lines, which uses a gimbal-mounted pendulum in the housing of the laser level, for this purpose.

<CIT> discloses a carrier system for stabilizing a payload such as a camera mounted on the carrier, the carrier being mounted on a movable object such as an unmanned aerial vehicle (a UAV).

<CIT> discloses a laser tool according to the preamble of Claim <NUM> of the appended claims.

A first aspect of the invention provides a laser tool according to Claim <NUM> of the appended claims.

A second aspect of the invention provides a laser tool system according to Claim <NUM> of the appended claims.

Preferred, and other optional, features of the invention are defined and described in the dependent claims.

The, or each, laser emitter preferably comprises a laser diode. The, or each, laser emitter may, for example, comprise an assembly comprising a laser diode and at least one optical component, e.g. a lens, preferably a collimating lens. The, or each, laser emitter assembly may include an enclosure which holds the laser diode and the, or each, optical component, and which includes at least one opening to allow the laser beam to be emitted from the assembly.

The housing preferably fully contains the, or each, laser emitter, e.g. the, or each, laser emitter assembly. The housing preferably includes one or more windows to allow the, or each, laser beam to be emitted from the housing. Additionally or alternatively, at least one laser emitter may extend at least partially outside of the housing, for example in order to be able to rotate with respect to the housing, preferably for embodiments of the invention in which the laser tool is a rotary laser tool. The housing preferably is formed from plastics material.

The support may be a gimbal support, for example. The support preferably has exactly three non-parallel rotational axes for adjusting the support to orient the housing and thereby orient and position the laser beam.

The adjustment of the support to orient the housing and thereby orient and position the laser beam preferably is configured to be by means of: substantially horizontal rotation about a substantially vertical axis (e.g. panning between left and right, otherwise known as "yaw") and/or substantially vertical rotation about a substantially horizontal axis (e.g. tilting between up and down; otherwise known as "pitch") and/or substantially twisting rotation about a substantially horizontal axis (e.g. rolling clockwise or anti-clockwise).

The housing and the support preferably are configured to enable the housing to be detachably mounted to the support.

The support preferably comprises a single arm. For example, the support may comprise a gimbal arm, and/or robotic arm, and/or a stabilizer arm. A support in the form of a stabilizer, (either in the form of a single arm, or otherwise), preferably is configured to stabilize the housing against vibrations and/or impacts.

Advantageously, the arm may have two or more joints, for example.

For example, the jointed arm may be joined to the base by means of a pivot enabling relative rotation between the jointed arm and the base about a substantially vertical axis.

Each powered pivot may comprise a brushless and/or electronically commutated motor. Each motor preferably is housed within the support.

The support, or at least the structural and/or weight-bearing parts thereof, preferably is/are formed from a plastics material; however, the support may additionally or alternatively comprise metal, for example.

The laser tool of the invention preferably comprises one or more gyroscopes, and/or at least one inertial measurement unit (IMU), configured to enable the orientation of the laser beam, e.g. with respect to gravity. Preferably, at least one said gyroscope and/or inertial measurement unit is located in or on the arm and/or the housing. Preferably, at least one accelerometer and/or gyroscope, and/or at least one inertial measurement unit (IMU), is located in or on the arm at an opposite end region of the arm to the base. Advantageously, at least one accelerometer and/or gyroscope, and/or at least one inertial measurement unit (IMU), is located in or on at least one pivot of the arm.

The laser tool preferably further comprises at least one microprocessor, preferably located in the support and/or the housing, configured to control the adjustment of the support to orient the laser beam utilising orientation and/or movement information provided by the at least one accelerometer and/or gyroscope and/or inertial measurement unit.

The laser tool preferably further comprises one or more human-usable controls for controlling and/or setting the adjustment of the support and/or for controlling the laser emitter. The, or each, control may be located on the support, preferably on the base, and/or on the housing, and/or comprises a remote control, e.g. in the form of a software application installed on a mobile device, preferably configured to communicate with the remainder of the tool via wireless electromagnetic wave communication, e.g. Bluetooth. The remote control (where present) may be removably attached, or attachable, to the support, preferably the base.

The laser tool preferably further comprises at least one power source, preferably at least one battery pack and/or battery cell, mounted or mountable therein or thereon. Advantageously, a single power source may be configured to power both the laser emitter and the, or each, pivot, for example. The power source preferably is mounted in, or mountable on, the support, preferably the base, and preferably is removably so mounted or mountable.

The remote control (where present) preferably includes a chargeable battery which is configured to be chargeable by the power source when the remote control is attached to the support and the power source is mounted in or on the support.

In some embodiments of the invention, the base of the support may comprise or include a handle, by which the laser tool may be held, e.g. for positioning and/or using and/or carrying the tool. The base may be configured for supporting the tool on a surface, e.g. via a bottom surface, or one or more legs and/or via an attachment configured to attach the tool to a tripod or bracket or other mount, for example.

The laser tool comprises a laser level. The laser level is a spot (point) laser and/or a line laser and/or a rotary laser, configured to emit one or more laser beams to project one or more laser spots and/or laser lines on external surfaces, e.g. walls and/or floors and/or ceilings. For example, the, or each, laser emitter may include a substantially cylindrical lens or a substantially conical reflector, to project one or more laser lines on external surfaces. Alternatively or additionally, at least one laser emitter may be configured to rotate or oscillate, or to emit a laser beam onto a rotating or oscillating reflector, by means of at least one motor of the laser tool, to project one or more laser lines on external surfaces.

The laser level is configured to emit one or more laser beams in horizontal and/or vertical orientations with respect to gravity.

Additionally, the laser tool may be configured to emit one or more laser beams at any predetermined and/or adjustable orientation with respect to gravity.

Because the support enables the orienting and positioning of the laser beams(s) emitted from the housing, in at least some embodiments of the invention the housing and its content can be relatively simple, small and lightweight, for example. In at least some preferred embodiments of the invention, the housing does not include a pendulum for alignment of the laser beam(s) with respect to gravity. For example, the housing may include substantially only the laser emitter(s) and electrical conductors to provide electrical current to the emitter(s), and optionally any other electronic and/or optical device(s), e.g. one or more cameras and/or electronic circuitry (e.g. one or more microprocessors and/or one or more accelerometers). However, in other embodiments of the invention, the housing may include a pendulum for alignment of the laser beam(s) with respect to gravity.

In some preferred embodiments of the invention, the laser tool may additionally comprise a laser distance measurer (LDM) and/or a laser rangefinder and/or a LIDAR tool and/or a laser scanner, for example.

In at least some preferred embodiments of the invention, the laser tool may include a camera in or on the housing and/or the support.

In at least some preferred embodiments of the invention, the laser tool may be configured to measure and/or scan and/or map a room or other space.

In at least some preferred embodiments of the invention, the laser tool may be configured to track motion external to the laser tool, e.g. by means of a camera of the laser tool, and/or to stabilize motion of the laser tool.

In at least some preferred embodiments of the invention, the laser tool is programmable. For example, in some embodiments of the invention, the laser tool may be programmable for setting and/or saving specific orientations and/or movements of the housing and/or specific orientations and/or positions and/or movements of the laser beam(s). In some programmable or programmed movements, one or more pivots may not rotate (e.g. they may be "locked-out" from rotation), for example to enable rotations about only one or two axes, especially for purely horizontal or purely vertical rotations.

In at least some preferred embodiments of the invention, the at least one laser emitter and the housing comprise a laser unit (e.g. a first laser unit), and wherein the laser unit and the support are configured to enable the laser unit to be detachably mounted to the support.

Preferably, the laser unit does not include a pendulum for alignment with respect to gravity.

The laser tool system according to the second aspect of the invention enables, for example, one of a plurality of laser units, preferably different types of laser unit, of the system to be detachably mounted to the support at any one time, depending on the specific user needs at that time. Because the support enables the orienting and positioning of the laser beams(s) emitted from the supported laser unit, each laser unit can be relatively simple, small and lightweight, for example. As indicated above, in at least some preferred embodiments of the invention, the laser units do not include a pendulum for alignment with respect to gravity. For example, the laser units may include substantially only the laser emitter(s) and electrical conductors to provide electrical current to the emitter(s), and optionally any other electronic and/or optical device(s), e.g. one or more cameras and/or electronic circuitry (e.g. one or more microprocessors).

Advantageously, the laser tool system preferably further comprises at least a third laser unit, preferably different to each of the first and second laser units, comprising at least one third laser emitter for emitting at least one laser beam from the third laser unit; and a third housing, supporting and at least partially containing the third laser emitter; wherein the third laser unit and the support are configured to enable the third laser unit to be detachably mounted to the support.

Advantageously, each laser unit of the laser tool system may comprise a laser unit selected from: a spot-laser unit; a line-laser unit; a cross-line laser unit; a combination spotand line-laser unit; a <NUM> degrees line-laser unit; a rotary-laser unit; an oscillating-laser unit; a red-laser unit; a green-laser unit; a laser distance measurer (LDM) laser unit; a laserscanner laser unit.

Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, of which:.

In the figures and the following description, the same, or functionally the same or similar, features share the same reference numerals. <FIG>, <FIG>, <FIG> and <FIG> show four views of a first exemplary embodiment of a laser tool <NUM> according to the invention. (For clarity, reference is also made to some features illustrated in <FIG>, <FIG> and <FIG>. ) The laser tool <NUM> of the first exemplary embodiment includes at least one laser emitter <NUM>, and preferably a plurality of laser emitters <NUM>, as schematically shown in <FIG>, for emitting either one or two laser beam(s) <NUM> from the tool, as described in more detail below. (The laser beams are not illustrated in <FIG>, but are schematically illustrated in <FIG>. ) The laser tool <NUM> also includes a housing <NUM> which supports and contains the laser emitter(s) <NUM>. The laser tool <NUM> further includes a support <NUM> which is external to the housing <NUM>, and which is configured to support the housing. As described in detail below, and as shown in the figures, the support <NUM> is adjustable for orienting the housing <NUM> and thereby orienting and positioning the laser beam(s) <NUM>. The housing <NUM> and laser emitter(s) <NUM> together comprise a laser unit <NUM>.

The, or each, laser emitter <NUM> comprises at least a laser diode, and preferably comprises an assembly comprising a laser diode and at least one or more optical components, preferably including at least a collimating lens. In at least some embodiments of the invention, the, or each, laser emitter <NUM> may, for example, include a generally cylindrical lens or a generally conical reflector, configured to convert a "spot" cross-section laser beam into a "line" cross-section laser beam, thereby to project a laser line (at the desired orientation, e.g. horizontal or vertical, or another orientation) against an external surface. The, or each, laser emitter assembly generally includes an enclosure which holds the laser diode and the optical component(s), and which includes at least one opening to allow the laser beam to be emitted from the assembly. In the example embodiments of the invention shown in the figures, the housing fully contains the, or each, laser emitter <NUM>. However, in other embodiments of the invention, the, or each, laser emitter <NUM> may, for example, partially extend out of the housing, depending on design and use requirements, e.g. for those embodiments where the laser tool is a rotary laser. The laser emitter(s) <NUM> will not be described in further detail, because they are well known and used by persons skilled in the art of laser tools.

As already indicated, the first embodiment of the invention shown in <FIG> includes two laser emitters <NUM>, configured to project mutually perpendicular laser lines <NUM> and <NUM> (e.g. as illustrated in <FIG>). For this purpose, the laser emitters <NUM> of the first embodiment each include a cylindrical lens, and the housing <NUM> includes two mutually perpendicular elongate windows <NUM> to allow the two laser beams to be emitted from the tool. During use, both laser beams <NUM> may be emitted at the same time, to project a cross of two lines <NUM> and <NUM> on a wall <NUM> or other surface, or the user may choose to have only one laser beam <NUM> emitted, to generate a single laser line <NUM> or <NUM>, for example. The housing <NUM> may optionally include one or more cameras and/or laser distance measurers (LDMs), indicated by reference numeral <NUM>.

The illustrated support <NUM> is a gimbal support, in the form of a single jointed arm <NUM> which pivotably extends from a base <NUM> of the support. The base <NUM> includes a bottom surface <NUM> on which the laser tool <NUM> may be supported on a surface. The bottom surface <NUM> of the base <NUM> also includes a conventional attachment aperture <NUM> to enable the support <NUM>, and hence the laser tool <NUM>, to be mounted on a tripod or other bracket or mount (not shown). Additionally, the base <NUM> includes magnets <NUM>, for attaching the base to a ferrous metal mount or other structure. The base <NUM> may also function as a handle or holder for holding the laser tool <NUM> during use and/or for positioning/orienting the tool and/or for carrying the tool.

The jointed arm <NUM> of the support <NUM> is joined to the base <NUM> by means of a first pivot <NUM> which enables relative rotation between the jointed arm <NUM> and the base <NUM> about a first rotational axis A. Rotational axis A is preferably (but not always necessarily) generally or substantially vertical in use. A first section <NUM> of the jointed arm extends generally upwardly from the first pivot <NUM> via a bent section <NUM>. A distal end of the first section <NUM> of the arm <NUM> comprises a second pivot <NUM>, having a second rotational axis B. A second section <NUM> of the arm <NUM> extends from the second pivot <NUM> to a distal end region of the second section <NUM>, which has a third pivot <NUM>. Third pivot <NUM> has a third rotational axis C, about which a mounting portion <NUM> of the arm is able to rotate, in use. The mounting portion <NUM>, which for example may comprise one or more clips and/or detents and/or magnets (not shown), is configured to enable the detachable mounting of the housing <NUM> to the support <NUM>.

Each of the pivots <NUM>, <NUM> and <NUM> includes a motor <NUM> housed within the support <NUM>, preferably an electronically commutated brushless motor, configured to power the respective relative rotations about the axes A, B and C, in use, to adjust the support <NUM> to orient the housing <NUM> and thereby to orient and position the laser beam(s) <NUM>. Optionally, the pivots may also be rotated manually, thereby to adjust the support manually to orient the housing <NUM>, to orient and position the laser beam(s) <NUM>.

The adjustment of the support <NUM> to orient the housing <NUM> and thereby orient and position the laser beam preferably is configured to be by means of: generally or substantially horizontal rotation about a generally or substantially vertical axis (e.g. panning between left and right); and/or generally or substantially vertical rotation about a generally or substantially horizontal axis (e.g. tilting between up and down) and/or generally or substantially twisting rotation about a generally or substantially horizontal axis (e.g. rolling clockwise or anti-clockwise). However, the preferred motions of panning and/or tilting and/or rolling of the mounting portion <NUM> and the housing <NUM>, in order to arrive at the desired orientation and position of the emitted laser beam(s) may, at least in some embodiments of the invention, be carried out by a combination of motions, to arrive at a resultant movement.

The laser tools of the invention further comprise one or more accelerometers, e.g. with one or more gyroscopes, and/or at least one inertial measurement unit (IMU, comprising at least one accelerometer and at least one gyroscope), configured to enable the orientation of the laser beam(s) with respect to gravity. Such accelerometer(s) and/or IMU(s) preferably, therefore, comprise at least part of a control system of the laser tool, for controlling the adjustment of the support, and therefore the orientation of the housing, and thus, the position and orientation of the emitted laser beam(s). At least one accelerometer and/or inertial measurement unit is located in or on the arm and/or the housing. For example, the embodiment shown in <FIG> includes accelerometer units <NUM> in the second section <NUM> of the arm <NUM> and in the housing <NUM>. However, other locations for one or more accelerometers are possible, for determining orientations with respect to gravity, as will be understood by the skilled person. The accelerometer units <NUM> may comprises a plurality of accelerometers, e.g. three mutually perpendicular accelerometers.

Additionally, the rate and/or degree of rotation of each pivot of the supports of laser tools of the invention may be measured and/or controlled in order to control the adjustment of the support, and therefore the orientation of the housing, and thus, the position and orientation of the emitted laser beam(s). For example, for embodiments of the invention (e.g. such as the embodiment shown in <FIG>) in which each pivot includes a brushless and/or electronically commutated motor <NUM>, the adjustment of the support <NUM> may additionally be controlled by means of the degrees (amounts) of rotation of each motor <NUM>. Such degrees of rotation may, for example, be measured and controlled by means of Hall Effect sensors (not shown), or other known rotational or positional sensors, in or on the motors <NUM>, and/or may be carried out by means of the electronic control of the brushless and/or electronically commutated motors <NUM>, as will be understood by the skilled person.

Laser tools according to the invention preferably also include at least one microprocessor and/or other electronics, preferably located in the support and/or the housing, configured to control the adjustment of the support to orient and position the laser beam(s), for example utilising orientation and/or movement information provided by at least one accelerometer <NUM> and/or inertial measurement unit and optional rotational or positional sensor (e.g. Hall Effect sensor). For example, the laser tool <NUM> shown in <FIG> includes a microprocessor <NUM> located in the base <NUM> of the support <NUM>. In at least some preferred embodiments of the invention, the microprocessor <NUM> is programmable or preprogrammed to carry out any of a variety alignment and/or measurement and/or scanning operations, for example.

As described above, the laser tools of the invention preferably also include at least one power source, preferably at least one battery pack and/or battery cell, mounted or mountable in or on the laser tool. As shown in <FIG>, the base <NUM> of the embodiment of the invention shown in those figures has a rechargeable and removable power tool battery pack <NUM> mounted thereon. The support <NUM>, including the base <NUM>, contains electrical conductors configured to electrically connect the battery pack <NUM> with each electrical powerconsuming device of the laser tool <NUM>. The battery pack <NUM> is of the type configured to power a plurality of different types of power tool, including laser tools <NUM> according to the present invention, and as illustrated is preferably a "slide" type battery pack, i.e. which has a sliding attachment/detachment motion. The battery pack <NUM> is configured to power the laser emitters <NUM> and each pivot motor <NUM>. Additionally, the battery pack <NUM> is configured to power the microprocessor <NUM> and/or other electronics in the tool, for example (i.e. the entire tool). The battery pack <NUM> includes a spring-loaded depressible button <NUM> for unlatching and removing the battery pack from the base <NUM>.

Laser tools according to the invention preferably also include one or more human-usable controls for controlling and/or setting the adjustment of the support and/or for controlling the laser emitter. The, or each, control may be located on the support, preferably on the base, and/or on the housing, and/or may comprise a remote control, e.g. in the form of a software application installed on a mobile device, preferably configured to communicate with the remainder of the tool via wireless electromagnetic wave communication. For example, the base <NUM> of the laser tool <NUM> illustrated in <FIG> has a remote control device <NUM> removably attached thereto. The remote control device includes a plurality of controls <NUM>, for switching the laser beam(s) on and off, for orienting the housing <NUM> so that a vertical and/or horizontal laser line is projected, and for panning and tilting the housing to position the vertical and horizontal laser lines. The controls <NUM> may be used while the remote control device is attached to the base <NUM>, or the remote control device <NUM> may be removed from the base <NUM> so that the laser tool <NUM> can be controlled remotely. The remote control device <NUM> is configured to communicate with the support <NUM> of the laser tool <NUM> via electromagnetic wave communication, e.g. Bluetooth.

As already mentioned, for at least some embodiments of the invention, such as the embodiments shown in <FIG>, and the tool shown in <FIG> and <FIG>, the laser tool <NUM> is a cross-line laser level, meaning that the laser tool is generally configured to project a vertical laser line and/or a horizontal laser line onto surfaces (such as walls and/or ceilings and/or floors) external to the laser tool. For example, <FIG> shows another cross-line laser tool <NUM>, projecting a vertical laser line <NUM> against a wall <NUM>, and also shows the laser tool <NUM> projecting a horizontal laser line <NUM> against the wall <NUM>, to form perpendicular crossed laser lines. However, it is of course necessary to use different types of laser tools for different tasks, and the present invention also provides a laser tool system, for this purpose. <FIG> shows a second embodiment of a laser tool <NUM> according to the invention, comprising the same support <NUM>, battery pack <NUM> and remote control device <NUM> as the first embodiment shown in <FIG>, but the laser unit <NUM> of <FIG> has been removed from the support <NUM> and has been replaced with a different laser unit <NUM>. The laser unit <NUM> of <FIG> includes a laser emitter <NUM> having a conical reflector, for generating a <NUM> degree laser line. The embodiment of the invention shown in <FIG>, and the embodiment of the invention shown in <FIG>, together comprise an example of a laser tool system according to the invention, comprising a single support <NUM>, and two different laser units <NUM> which can be selectively (e.g. alternately or alternatively) mounted on the support <NUM>, depending on requirements.

<FIG> and <FIG> show a laser tool <NUM> not according to the invention, comprising a laser unit <NUM>, a support <NUM>, and a battery pack <NUM> mounted on the support <NUM>. In this tool, the support <NUM> includes an adjustable support portion in the form of a manually adjustable tripod <NUM>. In this tool, each leg <NUM> of the tripod <NUM> comprises a series of ball-joint elements <NUM>, which can be manipulated to adjust the shape of the leg, thereby to orient the housing <NUM> of the laser unit <NUM>, to orient and position the laser beam(s) <NUM> emitted from the laser tool during use. As indicated above, the laser unit <NUM> of <FIG> and <FIG> includes two laser emitters <NUM>, configured to project mutually perpendicular laser lines <NUM> and <NUM>. During use, both laser beams <NUM> may be emitted at the same time, to project a cross of two lines <NUM> and <NUM> on a wall <NUM> or other surface, or the user may choose to have only one laser beam <NUM> emitted, to generate a single laser line <NUM> or <NUM>, for example.

As mentioned above, laser tools and laser tool systems according to the invention may additionally comprise a laser distance measurer (LDM) and/or a laser rangefinder and/or a LIDAR tool and/or a laser scanner, for example.

In at least some embodiments of the invention, the laser tool or laser tool system may further comprise a camera in or on the housing, in or on a laser unit, and/or in or on the support, for example.

In at least some embodiments of the invention, the laser tool or laser tool system may be configured to measure and/or scan and/or map a room or other space.

In at least some embodiments of the invention, the laser tool or laser tool system may be configured to track motion external to the laser tool, e.g. by means of a camera of the laser tool, and/or to stabilize motion of the laser tool.

Claim 1:
A laser tool (<NUM>), comprising:
(a) at least one laser emitter (<NUM>), for emitting at least one laser beam from the tool;
(b) a housing (<NUM>), supporting and at least partially containing the laser emitter (<NUM>); and
(c) a support (<NUM>) external to the housing (<NUM>), for supporting the housing (<NUM>), wherein the support (<NUM>) comprises a jointed arm (<NUM>) which is adjustable for orienting the housing (<NUM>) and thereby orienting and positioning the laser beam, the support (<NUM>) further comprising a base (<NUM>) from which the jointed arm (<NUM>) extends, the jointed arm (<NUM>) being joined to the base (<NUM>) by means of a pivot (<NUM>), and at least one joint of the arm also comprising a pivot (<NUM>, <NUM>), each pivot enabling, respectively, relative rotation between the jointed arm (<NUM>) and the base (<NUM>), or between two sections (<NUM>, <NUM>) of the jointed arm (<NUM>), each about a rotational axis (A, B, C), wherein the support (<NUM>) has at least three mutually substantially perpendicular rotational axes (A, B, C), and each pivot (<NUM>, <NUM>, <NUM>) is powered by means of a motor (<NUM>) such that the relative rotations are powered; characterized in that the laser tool (<NUM>) is a spot laser level and/or a line laser level and/or a rotary laser level and further comprises one or more accelerometers (<NUM>) located in or on the support (<NUM>) and/or the housing (<NUM>) and configured to enable the orientation of the laser beam with respect to gravity and thereby to emit the laser beam in a horizontal and/or vertical orientation with respect to gravity to project one or more horizontal and/or vertical laser lines and/or laser spots on external surfaces.