Digital twin modeling method and device for water-guided laser coupling energy beam

Abstract

The invention belongs to the technical field of digital twinning modeling, and discloses a digital twinning modeling method and device for a water-guided laser coupling energy beam, measurement modules are integrated, a measurement system is modularly designed, a data interface is unified, and the overall reliability and maintainability are improved; the online monitoring real-time performance is high, online monitoring is carried out on coupling energy beams in the water-jet guided laser machining process, the system response speed is high, and the dynamic working condition requirement is met; the device is high in adaptability, and can be widely applied to various nozzle module structures, light path configuration and processing material scenes; and digital twinborn modeling and feedback control are supported: an edge calculation module is combined, data information of each detection module is processed, characteristic parameters of the coupled energy beam are extracted and serve as a data source of coupled state digital twinborn modeling, digital information of the coupled energy beam is output to a visual interface, and control over the technological process is enhanced.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of digital twin modeling, and particularly relates to a digital twin modeling method and device for water-guided laser coupling energy beams. BACKGROUND

[0002] The application relates to the technical field of water-guided laser, and particularly relates to a digital twin modeling method and device for real-time detection of the coupling energy beam state in a water-guided laser system.

[0003] The basic principle of a water-guided laser cutting device is to couple a high-power pulsed laser beam into a water jet to act on the surface of a workpiece to realize machining. The laser beam is output in an optical fiber coupling mode and is focused on a nozzle module arranged on the base of a disc-shaped water cavity (100-1000 um in thickness) through a lens. The cylindrical laminar water jet sprayed from the nozzle module is guided to act perpendicularly on the surface of the workpiece. The water-guided laser cutting device can produce a slit parallel to the cross section of the cut by the processing mode of laser and water jet coupling, thereby ensuring high machining precision and suppressing high temperature in the machining area.

[0004] Water-guided laser technology combines the high energy density of a laser beam with the good cooling and guiding characteristics of a water jet, and exhibits superior performance in micro machining. The geometric characteristics, spatial position and energy distribution of the coupling energy beam, such as the water jet radius measurement, water jet inclination degree, water light coupling effective length, water jet axis spatial coordinates and power density at different positions of the coupling energy beam, have a significant impact on the machining effect. However, the machining stability and consistency are subject to the following measurement and control bottlenecks:

[0005] 1. Water jet dynamic fluctuation is difficult to monitor: The stable length, inclination angle and radial fluctuation of the water jet have a significant impact on the laser propagation path, and traditional methods cannot obtain real-time data.

[0006] 2. Laser power distribution is difficult to detect: Existing technical solutions can only measure the total power before and after laser coupling, and cannot detect the distribution of laser energy in the water jet during the coupling process.

[0007] 3. Micro displacement of nozzle module causes focusing deviation: It is difficult to realize real-time sensing of the slight deviation of the posture of the nozzle module. During the movement of the nozzle module, the relative displacement between the laser focus point and the nozzle module hole occurs, which leads to focusing deviation and even burns the nozzle module.

[0008] 4. Each measurement system is independent and lacks a fusion mechanism: At present, power meters, image systems and inertial units are independent of each other, and there are problems such as data asynchronization, spatial misregistration and error accumulation.

[0009] The authorized invention patent CN118951406B water jet calibration method, system and water guide laser cutting equipment provides a water jet calibration method, system and water guide laser cutting equipment. The method first acquires a preset calibrator placed in the calibration area of the water guide laser cutting equipment; wherein the calibrator includes a reflective surface, a base and an arc surface part; the reflective surface is arranged on the protruding part of the base; then a coordinate system is constructed based on the projection point of the nozzle module on the calibrator as the origin, the first coordinate corresponding to the nozzle module under the coordinate system is acquired, and the nozzle module is controlled to emit a water jet to the calibrator, the water jet contacts the protruding part along the tangent of the arc surface of the arc surface part; then the optical sensor is controlled to acquire the critical reflection point of the water jet after the reflective surface, and the second coordinate of the critical reflection point under the coordinate system is acquired; finally, the inclination angle of the water jet is calculated by using the first coordinate and the second coordinate, and the coupling head is controlled to calibrate the water jet according to the inclination angle; the method is simple, fast, low in cost, and high in usability and reliability. However, the method has the following disadvantages: the control of the water jet along the tangent of the arc surface of the arc surface part contacting the protruding part is relatively complex, and the contact type measurement affects the stability of the water jet; the method of determining a straight line by two points lacks measurement of the radius of the water jet, and the coordinate measurement error of the two points in space will greatly affect the calculation of the inclination of the straight line.

[0010] The published invention patent CN120002178A water guide laser water light coupling correction method relates to a water guide laser water light coupling correction method, which comprises the following steps: performing first dotting on a light plate by a laser, performing second dotting after moving a focusing mirror module, calculating the deviation between the two positions by a control system, then adjusting the angle of a two-way mirror according to the deviation calculation result, and adjusting the angle of a nozzle module according to the test feedback of a detection optical module to make the water jet vertical. The present application adjusts the center of the nozzle module and the verticality with respect to the z-axis, and simultaneously adjusts the verticality of the laser beam itself. Thus, the problems between the focusing optical system and the nozzle module are overcome, the coupling of the laser beam and the water beam is detected and adjusted, and the structure is simpler in adjustment and use. However, the method has the following disadvantages: important parameters of the coupled energy beam are not measured.

[0011] Through the above analysis, the problems and defects of the prior art are as follows:

[0012] The prior art cannot realize multi-dimensional, unified and real-time monitoring of the water guide laser coupling state, and it is difficult to support process feedback and intelligent regulation and control under complex working conditions. SUMMARY

[0013] In view of the problems of the prior art, the present application provides a digital twin modeling method and device for water guide laser coupled energy beams.

[0014] The application is realized by a digital twin modeling method for water guide laser coupling energy beam, which comprises the following steps:

[0015] Step 1, system initialization and time synchronization:

[0016] All acquisition modules are synchronized by a unified clock in the edge computing module (such as PTP, NTP or 5G module); the time sequence consistency of multi-source data is ensured;

[0017] Step 2, water jet shape monitoring:

[0018] The high-speed imaging module continuously shoots water jet images; image preprocessing + edge recognition extracts shape features (water jet inclination angle, stable segment length, water jet diameter, etc.); and the water jet state (inclination, etc.) is output in real time;

[0019] Step 3, energy beam power density measurement;

[0020] Step 4, nozzle module posture solving;

[0021] Step 5, data fusion and analysis.

[0022] Further, the energy beam power density measurement:

[0023] After the laser beam is coupled with the water jet, it is totally reflected in the laminar flow area, showing a light-free area; in the water jet breaking area, the laser escapes from the water jet and irradiates on the multi-channel photodetector array; the output signal of the multi-channel photodetector array is proportional to the light intensity, the two-dimensional energy distribution at the cross section is calculated by collecting the output signal of the multi-channel photodetector array, the coupling efficiency and the uniformity of the energy distribution of the laser beam and the water jet are reflected, and the energy distribution of the total reflection of the laser beam in the laminar flow area is output to the edge computing module for inversion and reconstruction.

[0024] Further, the nozzle module posture solving:

[0025] The nozzle module is connected to the motion mechanism, and the spatial posture of the nozzle module will change with the change of the machining path, affecting the coupling effect with the laser beam; the inertial measurement unit (IMU) is connected to the nozzle module, outputting the motion angular velocity and acceleration of the nozzle module, the spatial pose information of the nozzle module output by the inertial measurement unit (IMU) is input to the edge computing module, the spatial pose is solved by using an extended Kalman filter (EKF) algorithm, the nozzle module offset vector is output, and it is judged whether the device is in an ideal axis state.

[0026] Further, the data fusion and analysis:

[0027] The image features obtained by the high-speed imaging module, the light intensity data obtained by the multi-channel photoelectric detector array and the IMU attitude information obtained by the inertial measurement unit (IMU) are filtered and fused by an edge computing module, the edge computing module integrates input data to reconstruct the water jet space form, inversely calculate the water-light coupling energy distribution state and solve the nozzle module space pose, constructs a digital twin model of the water guide laser processing process, monitors important parameters in the processing process in real time and guides the adjustment of process parameters in the processing process;

[0028] Another object of the present application is to provide a digital twin modeling device for water guide laser coupling energy beam, comprising:

[0029] Water guide laser processing assembly:

[0030] Laser (such as fiber laser, solid-state laser, etc.), nozzle module (water jet forming unit), focused light beam and water jet form coupling energy beam, which propagates to the surface of the workpiece in the form of laminar water jet;

[0031] Multi-channel photoelectric detector array:

[0032] The multi-channel photoelectric detector array is arranged in a ring-shaped distribution along the axis of the coupling energy beam, and collects power distribution information of the laser beam passing through the scattering area of the water jet; the multi-channel photoelectric detector array does not directly contact the water jet or the laser; neutral attenuation sheets and optical collimating sheets are used for light intensity adjustment and protection; non-destructive and high-resolution power density measurement of laser energy distribution in the water jet is realized; laser energy distribution information is collected, and two-dimensional power density inversion is realized in combination with the edge computing module;

[0033] High-speed imaging module: a high-speed camera laterally photographs a water jet area, acquires an original image and identifies an image contour; image features are extracted to realize extraction of parameters such as water jet inclination angle, stable section length and water jet diameter; feature analysis is completed in combination with an image processing algorithm (such as Canny edge detection and morphological filtering);

[0034] Inertial measurement unit (IMU):

[0035] The inertial measurement unit (IMU) is installed on the nozzle module, and real-time spatial position (xyz coordinates) and spatial attitude (Pitch, Yaw, Roll) and acceleration information of the nozzle module are acquired; the coupling condition of the laser beam and the water jet is monitored, and the position and attitude of the nozzle module are adjusted in real time to ensure stable coupling; the inertial measurement unit (IMU) and the high-speed imaging module have a posture calculation and compensation mechanism: the real-time attitude deviation of the nozzle module reflects the coupling deviation condition of the laser energy beam and the water jet, the spatial pose of the nozzle module is adjusted, the spatial position and attitude of the water jet are corrected, the coupling of the water jet and the laser is ensured, and a basis is provided for closed-loop calibration of the motion system and processing error compensation;

[0036] Edge computing module:

[0037] An embedded high-performance processor is adopted; synchronization fusion and calculation of multi-source heterogeneous data from a multi-channel photoelectric detector array, a high-speed imaging module and an inertial measurement unit (IMU) are realized; the calculation results are output and pushed to an upper computer to be presented in a visual manner; a sliding window mechanism is introduced in the edge computing module to process asynchronous data, EKF is used in the fusion model to improve dynamic robustness, and long-term data accumulation is supported to form a machining process knowledge graph, thereby providing a reliable knowledge source for the digital twin modeling of the water guide laser machining process.

[0038] Another object of the present application is to provide a computer device comprising a memory and a processor, wherein the memory stores a computer program, and the computer program is executed by the processor to enable the processor to perform the steps of the digital twin modeling method of the water guide laser coupled energy beam.

[0039] Another object of the present application is to provide a computer readable storage medium storing a computer program, wherein the computer program is executed by a processor to enable the processor to perform the steps of the digital twin modeling method of the water guide laser coupled energy beam.

[0040] Another object of the present application is to provide an information data processing terminal for realizing the digital twin modeling device of the water guide laser coupled energy beam.

[0041] In combination with the above technical solutions and solved technical problems, the technical solution to be protected by the present application has the following advantages and positive effects:

[0042] First, in view of the defects and deficiencies of the prior art, the present application provides a digital twin modeling method and device of a water guide laser coupled energy beam, which realizes the synchronous measurement and fusion reconstruction of multi-dimensional parameters such as energy beam power density, water jet shape and nozzle module attitude in a water jet laser system, and provides accurate and real-time data support for process control.

[0043] The method and device of the present application comprise the following key steps and modules:

[0044] The energy beam power density measurement module: a multi-channel photoelectric detector array is arranged below the coupling region to collect light intensity data at different spatial positions, and a two-dimensional power density map is reconstructed by an inversion algorithm; the multi-channel photoelectric detector array belongs to a non-contact measurement method, which does not interfere with the path of the water jet, and is also beneficial to online monitoring of the energy distribution of the coupled energy beam.

[0045] Water jet shape measurement module: high-speed microscopic camera side-viewing collection of water jet image, combined with image processing algorithm to extract jet stable length, diameter, cone angle and other geometric parameters; or using OCT to obtain water jet-laser interactive cross section in coupling area; high-speed microscopic camera belongs to non-contact measurement method, which will not interfere with the path of water jet, and is also conducive to online monitoring of the state of coupling energy beam.

[0046] Nozzle module pose measurement module: six-axis inertial measurement unit (IMU) real-time acquisition of acceleration and angular velocity of nozzle module, combined with image tracking results for attitude correction; the correction of nozzle module pose is conducive to the real-time adjustment of laser and water jet coupling.

[0047] Edge computing and fusion processing module: based on unified timestamp mechanism and extended Kalman filter algorithm (EKF), the above multi-source data (coupling energy beam power density, water jet shape, nozzle module attitude, etc.) are fused, error compensated and spatially reconstructed;

[0048] Output module: generate laser power density distribution map, water jet stability evaluation index, coupling offset trend analysis and other core results, and display through visual interface.

[0049] Compared with the prior art, the present application has the following advantages:

[0050] Integrated measurement module: modular design of measurement system, unified data interface, improved overall reliability and maintainability; strong real-time online monitoring: online monitoring of coupling energy beam in water guide laser processing process, fast system response speed, meeting the demand of dynamic working condition; strong adaptability: can be widely used in various nozzle module structures, optical path configurations and processing material scenes; support digital twin modeling and feedback control: combined with edge computing module, process data information of each detection module, extract feature parameters of coupling energy beam and use as data source of coupling state digital twin modeling, output digital information of coupling energy beam to visual interface, and strengthen control of process.

[0051] Secondly, the present application realizes the synchronous measurement and fusion reconstruction of the multi-dimensional parameters such as the energy beam power density, the water jet shape, the nozzle module attitude and the like in the water guide laser system through a digital twin modeling method and device for water guide laser coupling energy beam, and provides accurate and real-time data support for process control. The specific expected benefits include: integrating multiple measurement modules and calculation modules, realizing the quantitative measurement of parameters in the calibration process of the water guide laser processing system, intuitively displaying the key performance parameters of the water guide laser coupling energy beam in a visual manner, synchronizing the data in each dimension, reducing the cumulative error, and enhancing the reliability of the water guide laser processing system; fusing multi-dimensional data, modeling the water guide laser coupling energy beam, real-time monitoring the state of the water guide laser coupling energy beam, and combining the digital twin model to realize the online regulation and control of process parameters. The commercial value includes: promoting the application of water guide laser technology in the fields of aerospace, semiconductors and the like, having a wide market application prospect, and is expected to bring significant economic and social benefits.

[0052] The technical scheme of the present application fills the technical gap in process information acquisition and process parameter regulation in water guide laser processing at home and abroad. The traditional information acquisition of water light coupling energy beam is obtained by a single sensor separately measuring one dimension, the data is not synchronized, there is cumulative error, the reliability is poor, and online measurement and control cannot be realized; while the present application realizes the synchronous measurement and fusion reconstruction of the multi-dimensional parameters such as the energy beam power density, the water jet shape, the nozzle module attitude and the like in the water jet laser system through a digital twin modeling method and device for water guide laser coupling energy beam, and provides accurate and real-time data support for process control, and drives the process parameter change through the digital twin model to realize the online monitoring and online regulation of the processing process, solving the deficiencies of the prior art in reliability and real-time performance and the like.

[0053] The technical scheme of the present application solves the technical problems that have not been effectively solved for a long time. The traditional information acquisition of water light coupling energy beam is obtained by a single sensor separately measuring one dimension, the data needs to be measured offline, the data is not synchronized, there is cumulative error, the reliability is poor, and online measurement and control cannot be realized. While the present application realizes the synchronous measurement and fusion reconstruction of the multi-dimensional parameters such as the energy beam power density, the water jet shape, the nozzle module attitude and the like in the water jet laser system through a digital twin modeling method and device for water guide laser coupling energy beam, and provides accurate and real-time data support for process control, and drives the process parameter change through the digital twin model to realize the online monitoring and online regulation of the processing process, solving the deficiencies of the prior art in reliability and real-time performance and the like. BRIEF DESCRIPTION OF DRAWINGS

[0054] Figure 1The figure is a flow chart of the digital twin modeling method of the water guide laser coupled energy beam provided by the embodiment of the application.

[0055] Figure 2 The figure is a model view of the digital twin modeling device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0056] Figure 3 The figure is an industrial camera shooting angle view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0057] Figure 4 The figure is a micro-motion caliper measuring water jet radius view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0058] Figure 5 The figure is a water jet effective length calibration view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0059] Figure 6 The figure is a calibration process view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0060] Figure 7 The figure is an axonometric view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0061] Figure 8 The figure is a top view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0062] Figure 9 The figure is a water jet radius, angle and breaking length view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0063] Figure 10 The figure is an energy distribution view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application.

[0064] Figure 11 The figure is a nozzle pose view of the digital twin modeling method and device of the water guide laser coupled energy beam provided by the embodiment of the application. DETAILED DESCRIPTION

[0065] In order to make the purpose, technical scheme and advantages of the application more clear, the application will be further described in detail below with examples. It should be understood that the specific examples described here are only used to explain the application, and are not used to limit the application.

[0066] The present invention provides a digital twin modeling method and device for a water-guided laser coupled energy beam. These methods aim to achieve synchronous, non-contact measurement of parameters such as the power density, spatial position, and water jet stability of the coupled laser energy beam in a water-guided laser system, and to construct a high-precision dynamic characterization model to provide real-time feedback and control for precision laser machining processes.

[0067] like Figure 1 As shown, a digital twin modeling method for a water-guided laser coupled energy beam provided by an embodiment of the present invention includes:

[0068] S101, system initialization and time synchronization:

[0069] All acquisition modules are synchronized with a unified clock in the edge computing module (such as PTP, NTP or 5G module), ensuring the timing consistency of multi-source data.

[0070] S102, water jet morphology monitoring:

[0071] The high-speed imaging module continuously captures water jet images; image preprocessing + edge recognition extracts morphological features (water jet inclination angle, stable section length, water jet diameter, etc.); and real-time output of water jet status (inclination, etc.);

[0072] S103, energy beam power density measurement;

[0073] S104, nozzle module posture calculation;

[0074] S105, data fusion and analysis.

[0075] The energy beam power density measurement provided by the embodiment of the present invention:

[0076] After the laser beam is coupled with the water jet, it is totally reflected in the laminar flow area, appearing as a lightless area; in the water jet fragmentation area, the laser escapes from the water jet and shines on the multi-channel photodetector array; the multi-channel photodetector array outputs an electrical signal that is proportional to the light intensity. By collecting the output signal of the multi-channel photodetector array, the two-dimensional energy distribution of the laser at the cross section is calculated, reflecting the coupling efficiency of the laser beam and the water jet and the uniformity of the energy distribution, and outputting it to the edge computing module to invert and reconstruct the energy distribution of the laser beam totally reflected in the laminar flow area.

[0077] The nozzle module posture calculation provided by the embodiment of the present invention:

[0078] The nozzle module is connected to the motion mechanism, and the spatial pose of the nozzle module changes with the change of the machining path, which affects the coupling effect with the laser beam; the inertial measurement unit (IMU) is connected to the nozzle module, and outputs the angular velocity and acceleration of the motion of the nozzle module, and the inertial measurement unit (IMU) outputs the spatial pose information of the nozzle module to the edge computing module, and the spatial pose is calculated by using an extended Kalman filter (EKF) algorithm or the like, and an offset vector of the nozzle module is output, and it is judged whether the device is in an ideal axis state.

[0079] The data fusion and analysis provided by the embodiment of the application:

[0080] The image features obtained by the high-speed imaging module, the light intensity data obtained by the multi-channel photoelectric detector array and the IMU attitude information obtained by the inertial measurement unit (IMU) are filtered and fused by the edge computing module, the edge computing module integrates the input data to reconstruct the water jet spatial form, inversely calculates the water-light coupling energy distribution state, calculates the spatial pose of the nozzle module, constructs the digital twin model of the water-guided laser processing process, and monitors important parameters in the processing process in real time and guides the adjustment of process parameters in the processing process.

[0081] As shown in Figure 2 The embodiment of the application provides a digital twin modeling device for water-guided laser coupling energy beam, which comprises:

[0082] Water-guided laser processing assembly:

[0083] Laser (such as fiber laser, solid-state laser, etc.), nozzle module (water jet forming unit), focused light beam and water jet form coupling energy beam, which is propagated to the surface of the workpiece in the form of laminar water jet;

[0084] Multi-channel photoelectric detector array:

[0085] It is arranged in a ring shape along the axis of the coupling energy beam, and the power distribution information of the laser beam passing through the scattering area of the water jet is collected; the multi-channel photoelectric detector array does not directly contact the water jet or the laser; neutral attenuation sheets and optical collimating sheets are used for light intensity adjustment and protection; non-destructive and high-resolution power density measurement of laser energy distribution in the water jet is realized; the laser energy distribution information is collected, and two-dimensional power density inversion is realized in combination with the edge computing module;

[0086] High-speed imaging module: a high-speed camera laterally photographs a water jet area, acquires an original image and identifies an image contour; image features are extracted to realize extraction of parameters such as water jet inclination angle, stable section length and water jet diameter; feature analysis is completed in combination with an image processing algorithm (such as Canny edge detection and morphological filtering);

[0087] Inertial measurement unit (IMU):

[0088] Installed on the nozzle module, it obtains the spatial position (xyz coordinates), spatial attitude (pitch, yaw, roll) and acceleration information of the nozzle module in real time; monitors the coupling between the laser beam and the water jet and adjusts the position and attitude of the nozzle module in real time to ensure stable coupling; the inertial measurement unit (IMU) and the high-speed imaging module have an attitude calculation and compensation mechanism: the real-time attitude deviation of the nozzle module reflects the coupling offset between the laser beam and the water jet, adjusts the spatial position of the nozzle module, corrects the spatial position and attitude of the water jet, ensures the coupling between the water jet and the laser, and provides a basis for the closed-loop calibration of the motion system and compensation of processing errors;

[0089] Edge computing module:

[0090] It uses an embedded high-performance processor; it realizes the synchronous fusion and solution of multi-source heterogeneous data from multi-channel photodetector arrays, high-speed imaging modules, and inertial measurement units (IMUs), outputs the calculation results and pushes them to the host computer for visual presentation; the edge computing module introduces a sliding window mechanism to process asynchronous data, and uses EKF in the fusion model to improve dynamic robustness, and supports long-term data accumulation to form a knowledge graph of the processing process, providing a reliable knowledge source for the establishment of a digital twin model of the water-guided laser processing process.

[0091] Another object of the present invention is to provide a computer device, comprising a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor executes the steps of the digital twin modeling method of the water-guided laser coupled energy beam.

[0092] Another object of the present invention is to provide a computer-readable storage medium storing a computer program, which, when executed by a processor, enables the processor to perform the steps of the digital twin modeling method of the water-guided laser coupled energy beam.

[0093] Another object of the present invention is to provide an information data processing terminal, which is used to realize the digital twin modeling device of the water-guided laser coupled energy beam.

[0094] The present invention is specifically implemented:

[0095] 1. System composition

[0096] In this embodiment, the measurement system includes the following core components:

[0097] Water-guided laser processing device

[0098] Laser: Fiber laser, maximum power 100W, 532nm green light.

[0099] Nozzle module aperture: 0.05mm, water pressure control at 5MPa, pressure pulsation less than 0.15%

[0100] The laser generates a focused laser beam, the nozzle module generates a laminar water jet, the focused laser beam and the water jet form a coupled energy beam at the nozzle aperture, and the focused laser beam propagates in the laminar water jet to the surface of the workpiece in the form of total reflection.

[0101] Multi-channel photodetector array

[0102] Number of channels: 12 silicon photodiodes

[0103] Detection band: 400-1100nm, response time <10ns

[0104] Array layout: semicircular arc structure, installed 10mm below the nozzle module

[0105] Additional: each channel is equipped with an ND attenuator at the front end to ensure that the laser is not saturated

[0106] The multi-channel photodetector array is arranged in a ring-shaped distribution along the axis of the coupled energy beam, and collects the power distribution information of the laser beam passing through the scattering area of the water jet; the multi-channel photodetector array uses neutral attenuators and optical collimators for light intensity adjustment and protection, and does not directly contact the water jet or the laser, achieving non-destructive and high-resolution power density measurement of the energy distribution of the laser in the water jet; the multi-channel photodetector array collects two-dimensional laser energy distribution information, which is input to the edge computing module to realize the inversion of the axial distribution of the laser energy in the water jet.

[0107] High-speed imaging module

[0108] High-speed camera frequency 1000fps, using microscopic zoom lens; image acquisition is performed on the front and side (orthogonal to each other) of the nozzle module; coaxial LED backlight is used for illumination; the high-speed camera shoots the water jet area from the side to obtain the original image and identify the image profile; image features are extracted to realize the extraction of parameters such as water jet inclination angle, stable segment length, and water jet diameter; combined with image processing algorithms, a self-developed image analysis module based on Python+OpenCV (such as Canny edge detection, morphological filtering) is used to complete feature analysis.

[0109] Inertial measurement unit (IMU)

[0110] The inertial measurement unit (IMU) is installed on the nozzle module fixed structure and is strictly aligned with the machining coordinate system.

[0111] The spatial pose of the nozzle module is solved based on a quaternion + EKF filter, and real-time spatial position (x, y, z coordinates), spatial pose (Pitch, Yaw, Roll), and acceleration information of the nozzle module are obtained to realize real-time output of the three-axis angle of the nozzle module.

[0112] The inertial measurement unit (IMU) and the high-speed imaging module have a pose calculation and compensation mechanism: the real-time pose deviation of the nozzle module reflects the coupling deviation of the laser energy beam and the water jet, adjusts the spatial pose of the nozzle module, corrects the spatial position and pose of the water jet, ensures the coupling of the water jet and the laser, and provides a basis for closed-loop calibration of the motion system and compensation of processing errors.

[0113] Edge computing module

[0114] All modules, including the multi-channel photoelectric detection array, the high-speed imaging module, and the inertial measurement unit (IMU), implement a time synchronization mechanism based on a unified timestamp protocol (NTP).

[0115] The edge computing module uses an embedded high-performance processor to realize the synchronous fusion and solution of multi-source heterogeneous data from the multi-channel photoelectric detector array, the high-speed imaging module, and the inertial measurement unit (IMU). The edge computing module generates laser energy coupling power density cloud maps, water jet stability indexes, nozzle module offset vectors, and other outputs to the host computer platform. The edge computing module extracts multi-source data features, constructs a digital twin model of the coupled energy beam, and displays the water jet spatial model, the two-dimensional cross-sectional and axial section diagrams of the energy density distribution of the laser energy beam in the water jet, the nozzle module pose deviation indication and adjustment, and the important parameter list in a visual manner in Unity3D.

[0116] The edge computing module introduces a sliding window mechanism to process asynchronous data, uses EKF in the fusion model to improve dynamic robustness, and supports long-term data accumulation to form a processing process knowledge graph, providing a reliable knowledge source for the digital twin model of the water-guided laser processing process, and relying on data-driven to guide process parameter regulation.

[0117] As shown in FIG. 2, the measurement and operation process Figures 3-6

[0118] System initialization

[0119] After starting the water-guided laser processing device, adjust the nozzle module and the laser beam to ensure stable coupling of the laser beam and the water jet, and the high-speed imaging module, the multi-channel photoelectric detection array, the inertial measurement unit (IMU), and other modules complete self-checking and calibration in turn; the edge computing module synchronizes the timestamps of all sensors, and after ensuring the alignment of the data timing, the high-speed imaging module, the multi-channel photoelectric detection array, the inertial measurement unit (IMU), and other modules start data acquisition. ​

[0120] Pre-process calibration

[0121] When the system enters the processing state, the inertial measurement unit (IMU) automatically acquires the nozzle module attitude angle and determines whether it exceeds the set tolerance (±2°). If it exceeds the limit, it prompts to re-align.

[0122] Online monitoring during processing

[0123] After the laser of the water guide laser processing device emits, the focused light beam is coupled and propagated through the water jet, and a multi-channel photoelectric detection array collects the energy distribution in real time.

[0124] The high-speed imaging module continuously collects water jet images, extracts water jet morphological features (water jet tilt angle, stable segment length, water jet diameter, etc.) by using image preprocessing + edge recognition method, and outputs the water jet state in real time. The output data are output to the edge computing module, and the water jet tilt angle, water jet surface vibration frequency, and diameter stability are analyzed.

[0125] The nozzle module is connected to the motion mechanism, and the spatial attitude of the nozzle module changes with the change of the processing path, which affects the coupling effect with the laser beam. The inertial measurement unit (IMU) is connected to the nozzle module, and outputs the angular velocity and acceleration of the nozzle module. The spatial pose information of the nozzle module output by the inertial measurement unit (IMU) is output to the edge computing module, the spatial pose is calculated by using extended Kalman filter (EKF) algorithm, the nozzle module offset vector is output, and it is determined whether the device is in the ideal axis state. The edge computing module evaluates the laser beam offset trend and predicts its influence on the processing path by combining the MU attitude change measured by the inertial measurement unit (IMU) and the image morphological change obtained by the high-speed imaging module.

[0126] Data fusion and output

[0127] The edge computing module integrates the input data to reconstruct the water jet spatial form, inversely calculates the water-light coupling energy distribution, and calculates the spatial pose of the nozzle module. It monitors important parameters in the processing process in real time and guides the adjustment of process parameters in the processing process. After the edge computing module fuses the above-mentioned multi-modal data, it generates the water jet three-dimensional structure, the laser energy beam two-dimensional section graph and the axis section graph, and the nozzle module attitude in real time, and synchronously displays them in the upper computer visual software interface, to construct the digital twin model of the water guide laser processing process. If the cloud map deviates seriously or the power center unevenness exceeds the set threshold, the system automatically issues an alarm, and records the processing log for subsequent analysis.

[0128] The specific embodiments of the present application are shown in the accompanying drawings. Figure 7 , Figure 8 .

[0129] Figure 7This is an axonometric diagram of a digital twin modeling method and device for a water-guided laser coupled energy beam, including 1 multi-channel photodetector array, 2 high-speed imaging module, 3 nozzle module, and 4 inertial measurement unit.

[0130] The technical effects obtained by the embodiments of the present invention are expected to be as follows: Figure 9 、 Figure 10 、 Figure 11 shown.

[0131] like Figure 9 The high-speed imaging module captures the water jet's tilt angle, jet radius, and rupture length, and draws relevant jet information images to understand the dynamic change process and stability of the water jet;

[0132] like Figure 10 As shown in the figure, the multi-channel photodetector array measures the distribution of laser energy in the water jet, gives the energy distribution cloud map at different jet cross-section positions, and determines the energy distribution information of the coupled energy beam;

[0133] like Figure 11 As shown, the inertial measurement unit and the adjustment module are combined to adjust the nozzle module posture according to the coaxial vision image, and the water-light coupling situation is monitored in real time.

[0134] like Figure 7 As shown in the figure, the spatial layout of the overall device consists of a multi-channel photodetector array, a high-speed imaging unit, a nozzle assembly, and an inertial measurement unit arranged in a ring around the water-optical coupling working chamber. Each module is fixed to the same reference plane via a high-strength carbon fiber bracket, ensuring the coaxiality of the detection field of view and maintaining stable interaction between the laser beam and the water jet in a controlled environment. The circumferential sensor captures multidimensional physical quantities in real time, providing synchronized data streams for the digital twin model.

[0135] like Figure 8 As shown, the four-quadrant detectors are arranged at 90° intervals to increase the sampling density of the radial energy distribution and scattered signals. The nozzle assembly is connected to the base via a micro-scale six-degree-of-freedom platform. The platform's pitch, yaw, and roll are driven by a closed-loop attitude quaternion output by the inertial measurement unit, achieving micro-arc-level position correction. The high-speed imaging unit is placed at a radial position of 180° to correct parallax offset caused by thermal drift and ensure the spatiotemporal alignment of the image and detector signal.

[0136] like Figure 9 As shown in the figure, during the time-resolved imaging phase, a high-speed camera uses a 10μs shutter and a narrowband filter to capture the interface evolution of the water jet. As the jet discretizes, the algorithm first reconstructs the jet envelope based on edge sub-pixel fitting. Then, an adaptive Kalman filter removes background disturbances, obtaining the evolution curves of the tilt angle, equivalent radius, and rupture length. These curves are then fed into the digital twin core to guide the real-time update of the CFD-optical collaborative model.

[0137] As shown in Figure 10 , the photodetector array is coupled by an integrating sphere to measure the power density distribution of the coupling energy beam at different cross-sectional areas. After absolute radiation calibration, the detector output forms a two-dimensional energy flow density cloud map, which can intuitively reflect the energy coupling efficiency of the beam core and the water core interface and the edge energy annular drift, providing a basis for subsequent energy beam shaping strategies.

[0138] As shown in Figure 11 , the inertial measurement unit integrates three-axis gyroscopes and three-axis accelerometers to solve the nozzle attitude in real time through an extended Kalman filter. Once the water jet axis deviates from the coaxial reference, the controller immediately issues micro-displacement and micro-rotation instructions to the six-dimensional platform, causing the nozzle to rotate sub-degree compensation, ensuring that the laser-water jet coaxiality is maintained within 0.05°.

[0139] Integrating Figures 7-11 the data stream, the digital twin model takes the experimental-simulation bidirectional coupling as the core: on the one hand, the multi-modal data from the detector and imaging system continuously correct the fluid-optical coupling parameters; on the other hand, the jet instability mode and energy focusing position predicted by the model are fed back to the hardware layer through the early warning algorithm, driving the nozzle platform and beam shaping module to adjust collaboratively, thereby completing the coupling efficiency evaluation and process window optimization within milliseconds.

[0140] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited thereto, any modification, equivalent replacement and improvement made by those skilled in the art within the technical range disclosed by the present application, as long as it is within the spirit and principles of the present application, should be covered within the protection scope of the present application.

Claims

1. A digital twin modeling method for water-guided laser coupled energy beam, characterized in that: include: Step 1: System initialization and time synchronization: All acquisition modules are synchronized with the clock in the edge computing module to ensure the timing consistency of multi-source data. Step 2, water jet morphology monitoring: High-speed imaging module continuously captures water jet images; image preprocessing + edge recognition extracts morphological features; Real-time output of water jet status; Step 3, measuring the energy beam power density; Step 4, nozzle module posture calculation; Step 5: Data fusion and analysis.

2. The digital twin modeling method of water-guided laser coupled energy beam according to claim 1, characterized in that: The energy beam power density measurement: After the laser beam is coupled with the water jet, it is totally reflected in the laminar flow area, which appears as a lightless area. In the water jet breakup area, the laser escapes from the water jet and illuminates the multi-channel photodetector array. The electrical signal output by the multi-channel photodetector array is proportional to the light intensity. By collecting the output signals of the multi-channel photodetector array, the two-dimensional energy distribution of the laser at the cross section is calculated, reflecting the coupling efficiency between the laser beam and the water jet and the uniformity of the energy distribution. The signals are then output to the edge computing module to invert and reconstruct the energy distribution of the laser beam under total reflection in the laminar region.

3. The digital twin modeling method of water-guided laser coupled energy beam according to claim 1, characterized in that: The nozzle module posture solution: The nozzle module is connected to the motion mechanism. As the processing path changes, the spatial posture of the nozzle module will change, affecting the coupling effect with the laser beam. The inertial measurement unit (IMU) is connected to the nozzle module and outputs the angular velocity and acceleration of the nozzle module. The inertial measurement unit (IMU) outputs the spatial posture information of the nozzle module to the edge computing module, uses algorithms such as the extended Kalman filter (EKF) to solve the spatial posture, outputs the nozzle module offset vector, and determines whether the device is in an ideal axis state.

4. The digital twin modeling method of water-guided laser coupled energy beam according to claim 1, characterized in that: The data fusion and analysis: The image features obtained by the high-speed imaging module, the light intensity data obtained by the multi-channel photodetector array, and the IMU attitude information obtained by the inertial measurement unit (IMU) are filtered and fused by the edge computing module. The edge computing module integrates the input data to reconstruct the spatial morphology of the water jet, inversely calculate the water-light coupling energy distribution, and solve the spatial position of the nozzle module. It constructs a digital twin model of the water-guided laser machining process, monitors important parameters in the machining process in real time, and guides the adjustment of process parameters during the machining process.

5. A digital twin modeling device for a water-guided laser coupled energy beam that implements the digital twin modeling method for a water-guided laser coupled energy beam according to any one of claims 1 to 4, characterized in that: The digital twin modeling device of the water-guided laser coupled energy beam includes: Water-guided laser processing components: The laser, nozzle module, focused beam and water jet form a coupled energy beam, which propagates to the surface of the workpiece in the form of a laminar water jet; Multi-channel photodetector array: The array is arranged in a circular pattern along the axis of the coupled energy beam, collecting information on the power distribution of the laser beam passing through the scattering zone of the water jet. The multi-channel photodetector array does not come into direct contact with the water jet or the laser. Neutral attenuators and optical collimators are used for light intensity regulation and protection. Non-destructive, high-resolution power density measurement of the laser energy distribution in the water jet is achieved. Laser energy distribution information is collected and combined with an edge computing module to achieve two-dimensional power density inversion. High-speed imaging module: A high-speed camera shoots the water jet area from the side, acquires the original image, and identifies the image contour; extracts image features to extract parameters such as the water jet inclination angle, stable section length, and water jet diameter; and combines image processing algorithms to complete feature analysis; Inertial Measurement Unit: Installed on the nozzle module, it obtains the spatial position (xyz coordinates), spatial attitude (pitch, yaw, roll) and acceleration information of the nozzle module in real time; monitors the coupling between the laser beam and the water jet and adjusts the position and attitude of the nozzle module in real time to ensure stable coupling; the inertial measurement unit (IMU) and the high-speed imaging module have an attitude calculation and compensation mechanism: the real-time attitude deviation of the nozzle module reflects the coupling offset between the laser beam and the water jet, adjusts the spatial position of the nozzle module, corrects the spatial position and attitude of the water jet, ensures the coupling between the water jet and the laser, and provides a basis for the closed-loop calibration of the motion system and compensation of processing errors; Edge computing module: It uses an embedded high-performance processor; it realizes the synchronous fusion and solution of multi-source heterogeneous data from multi-channel photodetector arrays, high-speed imaging modules, and inertial measurement units (IMUs), outputs the calculation results and pushes them to the host computer for visual presentation; the edge computing module introduces a sliding window mechanism to process asynchronous data, and uses EKF in the fusion model to improve dynamic robustness, and supports long-term data accumulation to form a knowledge graph of the processing process, providing a reliable knowledge source for the establishment of a digital twin model of the water-guided laser processing process.

6. A computer device, characterized in that: The computer device includes a memory and a processor, the memory stores a computer program, and when the computer program is executed by the processor, the processor performs the steps of the digital twin modeling method of water-guided laser coupled energy beam according to any one of claims 1 to 4.

7. A computer-readable storage medium storing a computer program, wherein when the computer program is executed by a processor, the processor executes the steps of the digital twin modeling method of water-guided laser coupled energy beam according to any one of claims 1 to 4.

8. An information data processing terminal, characterized in that: The information data processing terminal is used to implement the digital twin modeling device of the water-guided laser coupled energy beam as described in claim 5.

Images