A fault detection method and an optical shaping module based on air tightness detection

Abstract

The application relates to a fault detection method, and belongs to the technical field of optical devices.The method comprises the following steps: S1, performing airtight treatment on an optical shaping module to form a closed cavity in the optical shaping module; S2, introducing gas into the optical shaping module to maintain a positive pressure in the optical shaping module; S3, monitoring a gas parameter in the optical shaping module in real time; and S4, if the gas parameter is suddenly changed, stopping the optical shaping module to check the optical shaping module.The application has the effects of realizing timely and effective detection of abnormalities of the optical shaping module, and effectively reducing the pollution or damage of internal optical elements when a fault occurs.

Description

Technical Field

[0001] This application relates to the field of optical device technology, and in particular to a fault detection method and an optical shaping module based on airtightness detection. Background Technology

[0002] Optical shaping modules are widely used in equipment for laser processing and additive manufacturing to collimate, focus, and reflect the laser beam to meet the requirements of the processing technology.

[0003] In such modules, optical components such as reflectors, collimators, and focusing lenses are typically encapsulated inside the module, effectively isolating them from external contaminants. In contrast, protective mirrors are located at the optical path exit, directly exposed to the processing environment, making them more susceptible to the adhesion of dust, fumes, and processing spatter.

[0004] During high-power laser processing, if contaminants adhere to the surface of the protective mirror, laser irradiation can cause the mirror to overheat and be damaged. If the protective mirror cracks or ablates, smoke, dust, and debris can enter the module and contaminate or damage the internal reflectors, collimating mirrors, and focusing mirrors, affecting optical path quality and potentially causing equipment shutdown.

[0005] Conventional equipment typically lacks real-time detection capabilities, usually only detecting module malfunctions after the laser stops emitting light. Current common detection methods rely on temperature sensors to monitor the temperature of optical components. However, this method suffers from significant lag; by the time the temperature reaches the warning threshold, the internal optical components may already be covered in contaminants or have suffered surface ablation, rendering them unusable. Summary of the Invention

[0006] In order to enable timely and effective detection of anomalies in the optical shaping module, and to effectively reduce the risk of contamination or damage to internal optical components when a fault occurs, this application provides a fault detection method and an optical shaping module based on airtightness detection.

[0007] The fault detection method provided in this application adopts the following technical solution: A fault detection method includes the following steps: S1. Perform airtight treatment on the optical shaping module to form a closed cavity inside the optical shaping module; S2. Introduce gas into the optical shaping module to maintain positive pressure inside the optical shaping module; S3. Real-time monitoring of gas parameters within the optical shaping module; S4. If the gas parameters change abruptly, stop the machine and check the optical shaping module.

[0008] By adopting the above technical solution, when gas parameters change abruptly, even if other functional components in the optical shaping module are operating normally and the temperature parameters are not abnormal, it is possible to immediately determine that the module's sealing status is abnormal or damaged (such as deformation, breakage, and cracking of the protective mirror). This allows for the rapid detection of potential faults in the early stages, avoiding the lag caused by waiting for changes in other detection parameters and improving the timeliness and accuracy of fault response. When the protective mirror is damaged by ablation and causes gas leakage, the positive pressure inside the module allows the leaking airflow to expel the smoke generated during the ablation process from the module immediately, while preventing dusty air from entering. This effectively prevents optical components such as reflectors, collimators, and focusing lenses from being contaminated or having their surfaces ablated, reducing the frequency of optical component replacements due to malfunctions and lowering maintenance costs.

[0009] Optionally, in step S3, the detected gas parameters include gas flow rate; Step S3 also includes: monitoring the temperature parameters of the endoscope assembly of the optical shaping module; Step S4 also includes: if the gas parameters remain stable but the temperature parameters reach the warning value, the laser power is reduced first; if the temperature parameters do not decrease after a period of time, the processing is paused and the operating status of the cooling system and the reflection of the workpiece are checked.

[0010] By adopting the above technical solution, when gas leakage occurs in the optical shaping module, even if the gas pressure value does not change significantly, the change in gas flow rate can be accurately captured. Therefore, using gas flow rate monitoring is beneficial to improving the sensitivity and reliability of detection.

[0011] Simultaneously, by introducing the monitoring of mirror group temperature parameters, complementary judgments can be made with gas parameters: When gas parameters change abruptly while temperature parameters remain stable, it indicates that the module's sealing condition may have been compromised, especially the protective mirror, which is highly likely to be damaged. The system should be stopped immediately to inspect the protective mirror and prevent contamination of internal optical components.

[0012] When the gas parameters are stable and the temperature parameters reach the warning value, the laser power is reduced to cool down. If the temperature does not drop after a period of time, the processing is suspended, and the operating status of the cooling system and the reflection of the workpiece during processing are checked to locate the cause of the fault.

[0013] By combining airflow and temperature detection, not only can fault points be located quickly and accurately, but temperature detection can also serve as a last line of defense in the event of airflow detection failure. This significantly improves the fault response and fault diagnosis speed of the optical shaping module, helps reduce abnormal damage to reflectors, collimators and focusing lenses, and shortens maintenance downtime.

[0014] The optical shaping module based on airtightness detection provided in this application adopts the following technical solution: An optical shaping module based on airtightness detection can realize the above-mentioned fault detection method. It includes a mirror housing, an air inlet connector connected to the mirror housing, a mirror unit sealed and installed inside the mirror housing, a protective mirror sealed and installed on the mirror housing, and an optical fiber connector unit sealed and connected to the mirror unit.

[0015] By adopting the above technical solution, a closed cavity can be formed inside the optical shaping module, maintaining a positive pressure gas environment. When the protective lens or sealing structure is damaged, the internal gas will leak rapidly, and the sudden change in gas flow can be detected in time, thus quickly identifying module abnormalities and avoiding delayed fault detection. At the same time, the positive pressure gas can promptly expel smoke and particles generated by the damage to the protective lens and prevent external dust from entering, reducing the risk of contamination to the lens assembly unit.

[0016] Optionally, the mirror assembly unit includes an inlet shaping component and an outlet shaping component. The inlet shaping component is sealed to the fiber optic connector unit and is used to collimate and focus the laser beam from the fiber optic connector unit. The outlet shaping component is used to reflect the beam processed by the inlet shaping component twice to change the propagation direction of the beam, and the outlet shaping component can adjust the second reflection angle of the beam.

[0017] By adopting the above technical solution, in multi-laser composite processing scenarios, multiple optical shaping modules can be arranged more compactly around the wire feed nozzle. It is only necessary to ensure that the incident direction of the light is parallel to the wire, and then adjust the refraction angle to make the beam enter the molten pool at an angle. Therefore, to keep the protective mirror away from the molten pool and reduce its risk of contamination from smoke, spatter, and thermal radiation damage, the appropriate collimating lens focal length and focusing lens focal length can be selected based on the required spot size and the laser core diameter. The entire optical path can be magnified, and then the reflection angle of the shaping component can be adjusted. The optical shaping module is then moved vertically upwards to ultimately achieve the desired spot size and keep the protective mirror away from the molten pool. This differs from existing optical shaping modules used in multi-laser composite processing scenarios. In existing modules, the laser is directly and obliquely injected into the molten pool. Therefore, when adjusting the protective mirror away from the molten pool, the optical shaping module needs to move obliquely upwards. This results in increased overall laser head size, even though the protective mirror is protected, thus affecting processing. Therefore, by employing the inlet and outlet shaping components of this application, the distance between the mirror assembly and the molten pool can be effectively increased without increasing the overall space occupied by the laser head, resulting in high reliability and applicability.

[0018] Optionally, the import shaping component includes a first mounting base, which is sealed on the lens housing. A first abutting sleeve is fitted inside the first mounting base. The first abutting sleeve is threadedly connected to the lens housing, and the first abutting sleeve presses against the first mounting base. The first mounting base is provided with an annular protrusion. The first mounting base is sealed with a first connecting sleeve. The first connecting sleeve is supported on the annular protrusion. The first connecting sleeve is provided with a second annular protrusion. The first connecting sleeve is sequentially fitted with a collimating lens, a first abutting pad, a focusing lens, and a second abutting pad. One end of the first connecting sleeve is threaded to a second abutting sleeve. The second abutting sleeve abuts against the second abutting pad. The inner side wall of the first mounting base is provided with a water-cooling groove, and the outer wall of the first connecting sleeve and the water-cooling groove form a sealed first water-cooling channel. The first mounting base is provided with a first water-cooling connector. The first connecting sleeve has a fixed sleeve inserted at the end away from the second abutment sleeve, and the first mounting base has a third abutment sleeve threadedly connected at the end away from the first abutment sleeve. The third abutment sleeve presses against the fixed sleeve, so that the fixed sleeve presses against the first connecting sleeve.

[0019] By adopting the above technical solution, during assembly, the collimating lens, the first abutment, the focusing lens, and the second abutment are first installed into the first connecting sleeve in sequence, and then the second abutment sleeve is screwed on tightly. The collimating lens abuts against the second annular protrusion, and the collimating lens, the first abutment, the focusing lens, and the second abutment are pressed against each other in the first connecting sleeve. Then, the first mounting base is installed on the lens housing, and the first clamping sleeve is inserted into the first mounting base. The first clamping sleeve is tightened to press the first mounting base, thereby quickly fixing the first mounting base to the lens housing. Next, insert the first connecting sleeve into the first mounting base, then insert the fixing sleeve into the top of the first connecting sleeve, then put the third abutting sleeve on the top of the first mounting base, and tighten the third abutting sleeve so that the fixing sleeve presses against the top of the first connecting base, while the fixing sleeve drives the first connecting sleeve to support the first annular protrusion.

[0020] During the assembly process of the shaping assembly, each optical element (collimating lens, focusing lens, etc.) can be sequentially fixed within the connecting sleeve, and reliably pressed together by the cooperation of the clamping sleeve and the clamping pad, ensuring the stability of the optical elements' position and uniform force during operation. Simultaneously, the first mounting base, the first connecting sleeve, the fixing sleeve, and multiple clamping sleeves form a multi-layered sealing structure through threaded and clamping engagement. This not only simplifies and speeds up the assembly process but also effectively ensures the airtightness of the optical element cavity and the sealing of the water-cooling channel, thereby preventing external dust, smoke, or coolant leakage from contaminating or damaging the optical module, thus improving the assembly reliability and operational safety of the assembly.

[0021] Optionally, the export shaping assembly includes a steering reflector, a first receiving groove is provided on the outer side wall of the mirror assembly housing, the steering reflector is located in the first receiving groove, and a clamping plate is bolted to the mirror assembly housing, the clamping plate sealingly clamping the steering reflector; The upper cover of the mirror assembly housing is connected to a mirror base via an adjusting component. The adjusting component is used to adjust the angle of the mirror base. The mirror base is equipped with an adjusting mirror. A second water-cooling channel is provided on the mirror base. A second water-cooling connector is provided on the mirror base. A wiring channel is provided on the upper cover of the mirror assembly housing. The upper cover of the mirror assembly housing is also provided with an air inlet connector and a third water-cooling connector. A wiring hole is also provided on the upper cover of the mirror assembly housing. The mirror assembly housing is equipped with a first temperature sensor for monitoring the temperature of the steering reflector, and the mirror mount is equipped with a second temperature sensor for monitoring the temperature of the regulating reflector.

[0022] By adopting the above technical solution, when fixing the steering reflector, the steering reflector is first placed into the first receiving groove and then the clamping plate is installed, which can complete the installation of the steering reflector, which is convenient for installation and can ensure the sealing.

[0023] When installing the mirror mount, simply install the adjusting mirror, the first temperature sensor, and the second water-cooling connector onto the external mirror mount. Then, install the mirror mount onto the top cover of the mirror assembly housing using the adjusting components. Next, connect the second and third water-cooling connectors with pipes, and connect the lines of the first and second temperature sensors to the connectors in the wiring holes. Use the adjusting components to adjust the mirror angle. Finally, directly insert the second temperature sensor into the mirror mount and fasten the top cover of the mirror assembly housing to complete the installation of the inverted shaping unit. Compared to the traditional method of installing or removing components one by one in a small optical shaping module, this method improves installation convenience and efficiency, and achieves an integrated design for mirror angle adjustment and pipeline routing, resulting in a high degree of integration. In subsequent maintenance, disassembly can be completed simply by removing the mounting base, which helps to improve subsequent maintenance efficiency.

[0024] Optionally, it also includes a connector, which has an annular support groove. The protective mirror is located in the annular support groove, and a sealing gasket is also provided in the annular support groove. Both sides of the connector are hinged with buckles and springs, and the buckles are connected to the springs. A second receiving groove is provided on the inner side wall of the lens assembly housing, and the second receiving groove extends to one side of the lens assembly housing. A snap-fit ​​groove is also provided on the outer wall of the lens assembly housing, and the snap-fit ​​groove corresponds one-to-one with the buckle. When the connector is inserted into the second receiving groove and the buckle is fastened to the receiving groove, the sealing gasket abuts against the protective mirror and the second receiving groove.

[0025] By adopting the above technical solution, when installing the protective lens, first place the protective lens into the annular support groove, then place the sealing gasket into the annular support groove. The protective lens supports the sealing gasket. Next, press the buckles on both sides simultaneously by hand. Then, insert the connector into the second receiving groove and release. At this time, the spring pushes the buckle to lock into the snap-fit ​​groove, while the sealing gasket presses the protective lens tightly. This facilitates assembly, maintenance, and replacement, and provides a good sealing effect.

[0026] Optionally, the mirror housing is further connected to a first dust cover, which is located below the protective mirror. The first dust cover is connected to an air knife, and the air outlet of the air knife is located below the first dust cover. The air knife and the first dust cover are connected to a second dust cover, and the air outlet of the air knife is located inside the second dust cover. A first ventilation groove is formed through the first dust cover on the side opposite to the air knife, and a second ventilation groove is formed through the second dust cover on the side opposite to the air knife. The first ventilation groove and the second ventilation groove are connected.

[0027] By adopting the above technical solution, the first and second dust covers form a multi-level barrier structure, which can initially block dust, smoke, and splashes from the processing area, reducing the risk of contamination to the protective mirror at the source. Simultaneously, the air knife continuously sprays airflow, which not only promptly blows away contaminants adhering to the inside of the dust cover, but also smoothly discharges the airflow and carried impurities through the first and second ventilation slots, preventing the airflow from generating eddies within the cover and blowing dust back onto the surface of the protective mirror. This achieves more efficient and stable protection for the protective mirror.

[0028] Optionally, the fiber optic connector unit includes a fiber optic socket, one end of which is inserted into the fixing sleeve and slidably connected to the first connecting sleeve. The fixing sleeve is coaxially rotatably connected to an adjusting sleeve, and the adjusting sleeve is threadedly connected to one end of the fiber optic socket that extends out of the fixing sleeve.

[0029] By adopting the above technical solution, the operator only needs to rotate the adjustment sleeve to move the fiber optic socket up and down along the axis, thereby conveniently adjusting the relative position between the light source and the collimating lens. The adjustment process is simple and intuitive, and no additional tools are required.

[0030] Optionally, the upper cover of the lens assembly housing is provided with at least two first mounting slots, and the lens mount is provided with at least two second mounting slots. The first mounting slots and the second mounting slots correspond one-to-one. Fixing blocks are bolted into both the first mounting slots and the second mounting slots, and connecting rods pass through the fixing blocks. The adjusting component includes several tension springs, which are located in the first mounting groove. The two ends of the tension springs are respectively hung on the two corresponding connecting rods. The upper cover of the lens assembly housing is threaded with three adjusting bolts. A ball socket is provided at the corner of the top surface of the lens base. Sliding grooves are also provided at the other two corners of the top surface of the lens base. Both sliding grooves are opened in the direction pointing to the ball socket. The mirror mount is also provided with a third mounting slot and a fourth mounting slot. The second water-cooling connector is installed in the third mounting slot. The fourth mounting slot extends through to the side of the mirror mount where the adjusting reflector is located and to the top of the mirror mount. The fourth mounting slot is connected to the third mounting slot. The lead wire of the second temperature sensor extends out to the fourth mounting slot.

[0031] By adopting the above technical solution, the angle of the mirror mount is adjusted by the cooperation of the tension spring and the adjusting bolt. The end of the tension spring is sleeved on the fixing rod to prevent the tension spring from falling off when under force, which improves the stability of the tension spring connection. Furthermore, the tension spring is located in the first mounting groove, which helps to save space.

[0032] The fixing block can be quickly installed and removed. When the tension spring needs to be replaced, there is no need to disassemble the top cover of the lens mount and lens assembly housing. The replacement can be completed simply by removing the fixing block, which shortens the installation time and reduces the complexity of operation.

[0033] The third mounting slot avoids the second water-cooling connector protruding from the mirror mount, saving space and making the internal space more compact. The fourth mounting slot can make way for the water pipes connecting the second and third water-cooling connectors, and the third mounting slot can restrain the water pipes connecting the second and third water-cooling connectors, preventing the water pipes from bending and interfering with the mirror mount adjustment.

[0034] In summary, this application includes at least one of the following beneficial technical effects: 1. When gas parameters change abruptly, even if other functional components in the optical shaping module are operating normally and the temperature parameters are not abnormal, it can immediately determine that the module's sealing condition is abnormal or damaged (such as deformation, breakage, and cracking of the protective mirror). This allows for the rapid detection of potential faults in the early stages, avoiding the lag caused by waiting for changes in other detection parameters and improving the timeliness and accuracy of fault response. 2. When the protective mirror is damaged by ablation and causes gas leakage, the positive pressure inside the module allows the leaking airflow to expel the smoke generated during the ablation process from the module in the first instance, while preventing dusty air from entering. This effectively prevents optical components such as reflectors, collimators, and focusing lenses from being contaminated or having their surfaces ablated, reducing the frequency of optical component replacement due to malfunctions and lowering maintenance costs. 3. When a gas leak occurs in the optical shaping module, even if the gas pressure value does not change significantly, the change in gas flow rate can be accurately captured. Therefore, using gas flow rate monitoring is beneficial to improving the sensitivity and reliability of detection. 4. By combining airflow and temperature detection, not only can the fault point be located quickly and accurately, but temperature detection can also serve as the last line of defense in the event of airflow detection failure. This significantly improves the fault response speed and fault diagnosis speed of the optical shaping module, helps reduce abnormal damage to mirrors, collimating lenses and focusing lenses, and helps shorten maintenance downtime. 5. Each component can be quickly and sealed, which not only meets the airtightness requirements of airtightness testing and significantly improves assembly and maintenance efficiency, but also effectively increases the distance between the protective mirror and the molten pool in multi-laser processes, providing more reliable protection while avoiding an increase in overall space occupation. Attached Figure Description

[0035] Figure 1 This is a flowchart of a fault detection method according to an embodiment of this application. Figure 2 This is a schematic diagram of the overall structure of an embodiment of this application.

[0036] Figure 3 This is a schematic diagram illustrating the structure of the lens assembly unit in an embodiment of this application.

[0037] Figure 4 yes Figure 3 An enlarged schematic diagram of part A in the middle.

[0038] Figure 5 This is a schematic diagram illustrating the structure of the first temperature sensor in an embodiment of this application.

[0039] Figure 6 This is a schematic diagram illustrating the structure of the mirror base in an embodiment of this application.

[0040] Figure 7 This is a schematic diagram illustrating the structure of the second temperature sensor in an embodiment of this application.

[0041] Figure 8 This is a schematic diagram illustrating the structure of the ball socket and the groove in an embodiment of this application.

[0042] Figure 9 This is a schematic diagram illustrating the structure of the first mounting slot in an embodiment of this application.

[0043] Figure 10 yes Figure 3 Enlarged diagram of part B.

[0044] Figure 11 This is a schematic diagram illustrating the structure of the snap-fit ​​groove and the snap fastener in an embodiment of this application. Explanation of reference numerals in the attached drawings: 1. Lens assembly housing; 11. Outer shell; 111. Third water-cooling channel; 112. First receiving channel; 113. Inspection port; 114. Inspection plate; 115. Second receiving channel; 116. Snap-fit ​​channel; 12. Top cover; 121. Plate body; 1211. First mounting channel; 1212. Wiring channel; 122. Cover; 13. Air inlet connector; 2. Lens assembly unit; 21. Guide shaping component; 211. First mounting base; 2111. Water-cooling channel; 212. 213. First clamping sleeve; 214. First annular protrusion; 215. First connecting sleeve; 216. Second annular protrusion; 217. First water-cooling channel; 218. First water-cooling connector; 219. Collimating lens; 210. First clamping pad; 2111. Focusing lens; 2112. Second clamping pad; 2113. Fixing sleeve; 2114. Third clamping sleeve; 22. Second clamping sleeve; 22. Outlet shaping assembly; 221. Turning reflector; 222. Clamping plate; 223. First temperature... Temperature sensor; 224, mirror mount; 2241, fifth mounting slot; 2242, sixth mounting slot; 2243, fourth mounting slot; 2244, third mounting slot; 2245, second water-cooling channel; 2246, second mounting slot; 2247, ball socket; 2248, slide groove; 225, second temperature sensor; 226, adjusting mirror; 227, second water-cooling connector; 228, fixing block; 229, connecting rod; 23, adjusting component; 231, tension spring; 232, adjustment 233. Bolt; 234. Fixing nut; 25. Tightening nut; 26. Annular washer; 27. Mounting block; 28. Cable routing hole; 29. ​​Third water-cooling connector; 20. Fiber optic connector unit; 20. Fiber optic socket; 21. Adjusting sleeve; 22. Protective mirror; 33. Plug socket; 24. Annular support groove; 25. Sealing washer; 26. Buckle; 27. Spring; 28. First dust cover; 29. ​​First ventilation slot; 20. Air knife; 21. Second dust cover; 22. Light outlet hole; 23. Second ventilation slot. Detailed Implementation

[0045] The following is in conjunction with the appendix Figure 1-11 This application will be described in further detail.

[0046] This application discloses a fault detection method.

[0047] like Figure 1 The fault detection method includes the following steps: S1. Perform airtight treatment on the optical shaping module to form a closed cavity inside the optical shaping module; Sealing gaskets are used to seal the optical shaping module housing and its connected components. For example, sealing gaskets are used between the top cover 12 and the housing, between the fiber optic plug and the housing, between the mirror assembly unit 2 and the housing, and between the protective mirror 4 and the housing.

[0048] S2. Introduce gas into the optical shaping module to maintain positive pressure inside the optical shaping module; The air inlet is sealed on the housing. Gas is introduced into the optical shaping module by an air pump. The gas can be nitrogen or dry air. If the air is directly drawn by the air pump, a drying and filtering device should be installed to prevent dust and moisture in the air from entering the optical shaping module. During implementation, the positive pressure can be 50Pa-300Pa higher than the external atmospheric pressure. In this embodiment, the internal air pressure of the optical shaping module is 100Pa higher than the external atmospheric pressure.

[0049] S3. Real-time monitoring of gas parameters within the optical shaping module and temperature parameters of the endoscope assembly within the optical shaping module; In this embodiment, gas flow rate is selected as the gas parameter to be detected. It can be monitored using a miniature mass flow meter installed in the air inlet pipe. The temperature of the mirror assembly is monitored by temperature sensors arranged within the shaping module. Multiple temperature sensors can be used, and depending on the actual situation, the temperature of the straight mirror 217, focusing mirror 219, and reflecting mirror can be monitored separately. This embodiment only monitors the temperature of the reflecting mirror. The temperature sensor should be placed close to the lens, and the external connection of the temperature sensor's wiring should also be sealed, for example, using a sealed connector.

[0050] S4. If the gas parameters change abruptly, stop the machine and check the optical shaping module; if the gas parameters remain stable but the temperature parameters reach the warning value, reduce the laser power first. If the temperature parameters do not decrease after a period of time, suspend processing and check the cooling system operation status and workpiece processing reflection.

[0051] When a sudden change in gas parameters is detected, i.e. a sudden increase in flow rate, even if the temperature parameters have not changed, it can be determined that there is a high probability of gas leakage / damage to the protective mirror 4 / damage to the seal inside the optical shaping module. At this time, the control system will immediately issue a shutdown command and prompt for maintenance. When the gas parameters remain stable and the temperature parameters reach the set warning value, the system first reduces the laser power, for example, from 100% to 70%, and observes for 10 seconds; if the temperature still does not drop, the processing is paused, and a prompt is made to check the operating status of the cooling system and the reflection of the workpiece.

[0052] The implementation principle of this application embodiment is as follows: it can quickly and accurately locate the fault point under the dual detection of airflow and temperature: when the airflow changes suddenly but the temperature stabilizes, it indicates that the protective mirror 4 may be damaged; when the airflow is stable but the temperature is too high, it indicates that the cooling system or workpiece reflection is abnormal. At the same time, when one detection fails, the other detection can still serve as a redundant defense, ensuring the reliability and safety of the system. Furthermore, when the protective mirror 4 is damaged by ablation and causes gas leakage, the positive pressure inside the module allows the leaking airflow to expel the smoke generated during the ablation process from the module in the first instance, while preventing dusty air from entering. This effectively prevents optical components such as the reflector, collimator 217, and focusing lens 219 from being contaminated or having their surfaces ablated, reducing the frequency of optical component replacements due to malfunctions and lowering maintenance costs.

[0053] This application also discloses an optical shaping module based on airtightness detection, used to implement the above-mentioned fault detection method.

[0054] like Figure 2 and Figure 3 The optical shaping module based on airtightness detection includes a lens housing 1, a lens unit 2, a fiber optic connector unit 3, and a protective lens 4. The lens housing 1 consists of an outer shell 11 and a top cover 12. The top surface of the outer shell 11 is designed as a stepped surface, and the right side of the outer shell 11 is a 45-degree inclined surface. The side of the top surface of the outer shell 11 with the lower height faces the 45-degree inclined surface. The bottom surface of the outer shell 11 is inclined away from the left side of the outer shell 11. An inspection port 113 is opened on the left side of the outer shell 11, and an inspection plate 114 is bolted and sealed at the inspection port 113.

[0055] In this embodiment of the application, the mirror assembly unit 2 includes an inlet shaping component 21 and an outlet shaping component 22. The inlet shaping component 21 is sealed and installed on the side of the housing 11 with a lower height. The fiber optic connector unit 3 is sealed and installed on the inlet shaping component 21. The inlet shaping component 21 is used to collimate and focus the laser beam from the fiber optic connector unit 3. The export shaping component 22 is installed on the upper cover 12 and the 45-degree inclined surface of the outer shell 11. The export shaping component 22 is used to reflect the light beam processed by the import shaping component 21 twice to change the propagation direction of the light beam, and the export shaping component 22 can adjust the second reflection angle of the light beam.

[0056] The protective mirror 4 is sealed and installed on the bottom surface of the housing 11. The upper cover 12 is bolted and sealed to the housing 11, and the upper cover 12 is sealed and installed with an air inlet connector 13.

[0057] It can form a closed cavity and maintain a positive pressure gas environment inside the optical shaping module. When the protective mirror 4 or the sealing structure is damaged, the internal gas will leak rapidly, and the sudden change in gas flow can be detected in time, thus quickly discovering the module abnormality and avoiding delayed fault detection. At the same time, the positive pressure gas can promptly expel the smoke and particles generated by the damage to the protective mirror 4 and prevent external dust from entering, reducing the risk of contamination to the mirror assembly unit 2.

[0058] Furthermore, in multi-laser composite processing scenarios, multiple optical shaping modules can be arranged more compactly around the wire feed nozzle. It is only necessary to ensure that the incident direction of the light is parallel to the wire. Based on the required spot size and the laser core diameter, appropriate collimating and focusing lens focal lengths are selected to magnify the entire optical path. Then, the reflection angle of the shaping assembly 22 is adjusted, and the optical shaping module is moved vertically upwards to achieve the desired spot size. This also keeps the protective mirror 4 away from the molten pool, reducing its risk of contamination from smoke, spatter, and thermal radiation damage. All of this is done without increasing the overall space occupied by the laser head.

[0059] In other embodiments, the lens unit 2 may only have a collimating lens and a focusing lens, the housing may be cylindrical, with a protective lens and a laser respectively sealed at both ends, the collimating lens and the focusing lens installed inside, and an air inlet pipe sealed to the circumference of the housing 11.

[0060] like Figure 2 and Figure 4 The shaping component 21 includes a first mounting base 211, which is a cylindrical body. The bottom of the first mounting base 211 has a protrusion for engaging with the outer casing 11 to prevent rotation. The first mounting base 211 is sealed to the side of the outer casing 11 with the lower height. A first clamping sleeve 212 is coaxially sleeved inside the first mounting base 211. Since the bottom of the inner wall of the first mounting base 211 is designed in a stepped shape, the first clamping sleeve 212 can be supported on the bottom wall of the first mounting base 211. The first clamping sleeve 212 is threadedly connected to the first mounting base 211. Several adjustment grooves are also provided on the inner wall of the first clamping sleeve 212. During installation, only a special tool is needed to tighten the first clamping sleeve 212 to complete the sealed connection between the first mounting base 211 and the outer casing 11. In other embodiments, the first mounting base 211 can also be directly bolted to the outer casing 11.

[0061] A first annular protrusion 213 protrudes from the middle of the inner side wall of the first mounting base 211. A first connecting sleeve 214 is coaxially sleeved inside the first mounting base 211. The first connecting sleeve 214 is a column, and the outer wall of the first connecting sleeve 214 is a stepped annular outer wall. The stepped surface of the outer wall of the first connecting sleeve 214 is sealed and supported on the first annular protrusion 213 of the first mounting base 211.

[0062] A water-cooling groove 2111 is also provided on the inner side wall of the first mounting base 211. The water-cooling groove 2111 is an annular groove. The water-cooling groove 2111 is located between the first annular protrusion 213 and the bottom of the inner wall of the first mounting base 211. The water-cooling groove 2111 and the smaller outer diameter part of the first connecting sleeve 214 together form the first water-cooling channel 215.

[0063] A third water-cooling channel 111 is provided on the top surface of the lower part of the outer casing 11. The third water-cooling channel 111 is connected to the first water-cooling channel 215, and the sealing gasket between the first mounting base 211 and the outer casing 11 surrounds the third water-cooling channel 111, so that the sealing gasket is not easily damaged under high temperature operating conditions. Two first water-cooling connectors 216 are sealed and connected on the outer wall of the first mounting base 211.

[0064] A second annular protrusion 2141 protrudes from the center of the inner wall of the first connecting sleeve 214. A collimating lens 217, a first abutting pad 218, a focusing lens 219, and a second abutting pad 2110 are sequentially fitted inside the first connecting sleeve 214. The collimating lens 217 abuts against the second annular protrusion 2141, the first abutting pad 218 abuts against the collimating lens 217, the focusing lens 219 abuts against the first abutting pad 218, and the second abutting pad 2110 abuts against the focusing lens 219. A second abutting sleeve 2114 is internally threaded to one end of the first connecting sleeve 214 near the top surface of the outer casing 11. The second abutting sleeve 2114 abuts against the second abutting pad 2110, thus completing the fixed installation of the focusing lens 219 and the collimating lens 217.

[0065] The top surface of the first connecting sleeve 214 protrudes from the top surface of the first mounting base 211. The top surface of the first connecting sleeve 214 is also provided with an annular stepped shape. A fixing sleeve 2112 is sealed and inserted at the annular step on the top surface of the first connecting sleeve 214. The outer circumferential surface of the fixing sleeve 2112 is a three-stage annular stepped shape. A third abutting sleeve 2113 is coaxially threaded onto the first mounting base 211. The third abutting sleeve 2113 presses against the first-stage stepped surface of the fixing sleeve 2112.

[0066] During the assembly process of the shaping assembly 21, each optical element (collimating lens 217, focusing lens 219, etc.) can be sequentially fixed in the connecting sleeve, and reliably pressed together by the cooperation of the clamping sleeve and the clamping pad, ensuring the stability of the optical element's position and the uniform force during operation. At the same time, the first mounting base 211, the first connecting sleeve 214, the fixing sleeve 2112, and multiple clamping sleeves form a multi-seal structure through threaded and clamping engagement, which not only simplifies and speeds up the assembly process, but also effectively ensures the airtightness of the optical element cavity and the sealing of the water cooling channel, thereby preventing external dust, smoke, or coolant leakage from contaminating or damaging the optical module, and improving the assembly reliability and safety of the assembly.

[0067] In other embodiments, the import shaping component 21 may also include a mounting shell. One end of the mounting shell may be directly threaded / bolted to the housing. Inside the mounting shell, the collimating lens, the gasket, and the focusing lens are installed one by one using a clamping method. The other end of the mounting shell is connected to the fiber optic connector unit 3.

[0068] like Figure 4The fiber optic connector unit 3 includes a fiber optic socket 31. The inner wall of the fiber optic socket 31 is a multi-level annular stepped shape. The fiber optic socket 31 is coaxially inserted into the fixing sleeve 2112 and the first connecting sleeve 214, and the fiber optic socket 31 is slidably connected to the first connecting sleeve 214. Specifically, the sliding connection is as follows: the first connecting sleeve 214 has a sliding groove along its length, and a sliding block is connected to the fiber optic socket 31, which is inserted into the sliding groove.

[0069] An adjusting sleeve 32 is coaxially rotatably connected to the fixed sleeve 2112. The adjusting sleeve 32 is threadedly connected to one end of the fiber optic socket 31 that extends out of the fixed sleeve 2112. The outer circumferential surface of the fiber optic socket 31 that extends out of the fixed sleeve 2112 is provided with a scale. The specific rotatable connection between the fixed sleeve 2112 and the adjusting sleeve 32 is such that installation channels are formed at the second-level stepped surface of the adjusting sleeve 32 and the fixed sleeve 2112, and at the third-level stepped surface of the adjusting sleeve 32 mating washer and the fixed sleeve 2112, respectively. Several ball bearings are arranged in the two installation channels.

[0070] During installation, the adjusting sleeve 32 and the fixing sleeve 2112 need to be assembled first, and then the guide shaping component 21 needs to be assembled. Simply rotate the adjusting sleeve 32 to move the fiber optic socket 31 up and down along the axis, thereby conveniently adjusting the relative position between the light source and the collimating lens 217. The adjustment process is simple and intuitive and requires no additional tools.

[0071] like Figure 3 and Figure 5 The shaping assembly 22 includes a steering reflector 221. A first receiving groove 112 is formed on the inner wall of the right side of the housing 11. The first receiving groove 112 is an annular stepped groove. The steering reflector 221 is placed in the area with a smaller inner diameter of the first receiving groove 112. A clamping plate 222 is bolted to the area with a larger inner diameter of the first receiving groove 112. Sealing gaskets are placed between the clamping plate 222, the steering reflector 221, and the housing 11. The clamping plate 222 is tightly abutted against the steering reflector 221. A groove is formed inside the housing 11 near the steering reflector 221. A first temperature sensor 223 for monitoring the temperature of the steering reflector 221 is inserted into the groove.

[0072] Figure 6 and Figure 7The upper cover 12 is connected to a mirror base 224 via an adjusting member 23. The adjusting member 23 is used to adjust the angle of the mirror base 224. The mirror base 224 is a near-right-angled triangular prism. The adjusting member 23 acts on the top surface of the mirror base 224. The inclined surface of the mirror base 224 faces the steering reflector 221. In this embodiment, the inclined angle of the inclined surface of the mirror base 224 is 33 degrees. The inclined surface of the mirror base 224 has a fifth mounting groove 2241 and a sixth mounting groove 2242. The fifth mounting groove 2241 and the sixth mounting groove 2242 are connected. A second temperature sensor 225 is inserted into the sixth mounting groove 2242. An adjusting reflector 226 is installed in the fifth mounting groove 2241. The adjusting reflector 226 is fixed to the mirror base 224 by the mounting frame.

[0073] The top surface of the mirror mount 224 has a fourth mounting groove 2243, which communicates with the sixth mounting groove 2242. The inclined surface of the mirror mount 224 facilitates the extension of the lead wire of the second temperature sensor 225 from the mirror mount 224. One side of the mirror mount 224 has a third mounting groove 2244, which communicates with the fourth mounting groove 2243. A second water-cooling channel 2245 is formed inside the mirror mount 224. Two second water-cooling connectors 227 are installed on the side of the mirror mount 224. One second water-cooling connector 227 is connected to the water inlet of the second water-cooling channel 2245, and the other second water-cooling connector 227 is connected to the water outlet of the second water-cooling channel 2245.

[0074] like Figure 8 and Figure 9 The top surface of the mirror base 224 has two second mounting grooves 2246, which are perpendicular to each other in length and extend to the top surface and one side of the mirror base 224. The bottom surface of the upper cover 12 has a first mounting groove 1211, which corresponds to the second mounting grooves 2246. Fixing blocks 228 are bolted into both the first mounting groove 1211 and the second mounting groove 2246, and connecting rods 229 pass through the fixing blocks 228. A ball socket 2247 is provided at one corner of the top surface of the mirror base 224, and sliding grooves 2248 are provided at the other two corners of the top surface of the mirror base 224. Both sliding grooves 2248 are provided in the direction pointing towards the ball socket 2247.

[0075] like Figure 6 and Figure 9 The adjusting component 23 includes four tension springs 231 and three adjusting bolts 232. Each pair of tension springs 231 forms a group. The two ends of the tension springs 231 are respectively hung on the same end of the connecting rod 229. The tension springs 231 in the same group are located in the same second mounting groove 2246, and the two tension springs 231 in the same group are respectively hung on one end of the connecting rod 229.

[0076] The bottom bolt of the upper cover 12 is fixed with a fixing nut 233. The adjusting bolt 232 corresponds to the fixing nut 233 one by one. The adjusting bolt 232 passes through the upper cover 12 and is threadedly connected to the fixing nut 233. One adjusting bolt 232 abuts against the ball socket 2247, and the other two adjusting bolts 232 abut against a sliding groove 2248. Each adjusting bolt 232 is threadedly connected with a tightening nut 234, which can abut against the top surface of the upper cover 12.

[0077] like Figure 4 and Figure 6 The upper cover 12 includes a plate 121 and a cover 122. The plate 121 is bolted to the outer shell 11. An adjusting bolt 232 passes through the plate 121. A first mounting groove 1211 is formed on the plate 121. The plate 121 is also provided with a wiring groove 1212, which is 1 / 4 of the total area of ​​the plate 121. An annular pad 24 is bolted to the plate 121. A mounting block 25 is bolted to the annular pad 24. An air inlet connector 13 and a third water cooling connector 27 are provided on the mounting block 25. A wiring hole 251 is formed on the mounting block 25.

[0078] The wiring hole 251 is used to install the wiring connector. The wiring of the first temperature sensor 223 and the second temperature sensor 225 passes through the wiring channel 1212 and the wiring hole 251 in sequence and connects to the wiring connector. The pipeline between the second water-cooling connector 227 and the third water-cooling connector 27 passes through the fourth mounting groove 2243, the wiring channel 1212 and the annular pad 24 in sequence. The cover 122 is bolted to the plate 121 and covers the three adjusting bolts 232.

[0079] When installing the mirror mount 224, simply install the adjusting mirror 226, the first temperature sensor 223, and the second water-cooling connector 227 onto the mirror mount 224 externally. Then, install the mirror mount 224 onto the top cover 12 via the adjusting component 23. Next, connect the second water-cooling connector 227 and the third water-cooling connector 27 with pipes, and connect the lines of the first temperature sensor 223 and the second temperature sensor to the connector of the wiring hole 251. Use the adjusting component 23 to adjust the angle of the adjusting mirror 226. Finally, directly insert the second temperature sensor 225 into the mirror mount 224 and fasten the top cover 12 onto the outer shell 11 to complete the installation of the guide shaping component 21. Compared to the traditional method of installing or removing components one by one in a small optical shaping module, this method improves installation convenience and efficiency, and achieves an integrated design for mirror angle adjustment and pipeline routing, resulting in a high degree of integration. In subsequent maintenance, disassembly can be completed simply by removing the mounting base, which helps to improve subsequent maintenance efficiency.

[0080] like Figure 10 and Figure 11A second receiving groove 115 is formed on the inner side wall of the bottom of the outer casing 11, extending to one side of the outer casing 11. Snap-fit ​​grooves 116 are also formed on the two side walls of the bottom of the outer casing 11. The second receiving groove 115 is located between the two snap-fit ​​grooves 116. A plug-in seat 5 is inserted into the second receiving groove 115, and an annular support groove 51 is formed on the plug-in seat 5. The annular support groove 51 is also a stepped annular groove, and its minimum inner diameter is larger than the inner diameter of the second receiving groove 115. The protective mirror 4 is placed inside the annular support groove 51, and a sealing gasket 52 is also supported on the protective mirror 4. When the annular support groove 51 is completely located inside the second receiving groove 115, the sealing gasket 52 abuts against the inner top wall of the second receiving groove 115, thus pressing the protective mirror 4 between the sealing gasket 52 and the annular support groove 51.

[0081] The plug-in base 5 is hinged to two sides outside the second receiving groove 115 with latches 53. The end of the latch 53 away from the outer shell 11 is connected to a spring 54, and the other end of the spring 54 is connected to the plug-in base 5. The latches 53 correspond one-to-one with the receiving grooves 116. When the latches 53 are locked into the receiving grooves 116, the sealing gasket 52 abuts against the protective mirror 4 and the second receiving groove 115.

[0082] When installing the protective mirror 4, first place the protective mirror 4 into the annular support groove 51, then place the sealing gasket 52 into the annular support groove 51. The protective mirror 4 supports the sealing gasket 52. Next, press the buckles 53 on both sides simultaneously by hand. Then, insert the connector 5 into the second receiving groove 115 and release. At this time, the spring 54 pushes the buckles 53 to lock into the snap-fit ​​groove 116, while the sealing gasket 52 presses the protective mirror 4 tightly. This facilitates assembly, maintenance, and replacement, and provides a good sealing effect.

[0083] like Figure 2 and Figure 10 The bottom of the outer shell 11 is bolted to a first dust cover 6, which is located below the protective mirror 4. The first dust cover 6 is bolted to an air knife 7, and the air outlet of the air knife 7 is located below the first dust cover 6. The air knife 7 and the first dust cover 6 are connected to a second dust cover 8. The second dust cover 8 is a concave cover 122, and the air outlet is located between the two side walls of the second dust cover 8. A light outlet 81 is opened at the bottom of the second dust cover 8. A first ventilation groove 61 is opened through the first dust cover 6 on the side opposite to the air knife 7, and a second ventilation groove 82 is opened through the second dust cover 8 on the side opposite to the air knife 7. The first ventilation groove 61 and the second ventilation groove 82 are connected.

[0084] The implementation principle of this application embodiment is as follows: each component can be quickly sealed and assembled, which not only meets the airtightness requirements of airtightness testing and significantly improves assembly and maintenance efficiency, but also effectively increases the distance between the protective mirror 4 and the molten pool in multi-laser processes, providing more reliable protection while avoiding an increase in overall space occupation.

[0085] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An optical reshaping module based on gas tightness detection, characterized by: It includes a mirror housing (1), an air inlet connector (13) connected to the mirror housing (1), a mirror unit (2) sealed inside the mirror housing (1), a protective mirror (4) sealed on the mirror housing (1), and an optical fiber connector unit (3) sealed to the mirror unit (2). The lens assembly unit (2) includes an import shaping component (21) and an export shaping component (22); The import shaping component (21) includes a first mounting base (211), which is sealed on the lens housing (1). A first abutting sleeve (212) is fitted inside the first mounting base (211). The first abutting sleeve (212) is threadedly connected to the lens housing (1), and the first abutting sleeve (212) presses against the first mounting base (211). The first mounting base (211) is provided with a first annular protrusion (213), and a first connecting sleeve (214) is provided in the first mounting base (211). The first connecting sleeve (214) is supported on the first annular protrusion (213). The first connecting sleeve (214) is provided with a second annular protrusion (2141). The first connecting sleeve (214) is provided with a collimating lens (217), a first abutting pad (218), a focusing lens (219), and a second abutting pad (2110) in sequence. One end of the first connecting sleeve (214) is threadedly connected to the second abutting sleeve (2114), and the second abutting sleeve (2114) abuts against the second abutting pad (2110). The inner wall of the first mounting base (211) is provided with a water cooling groove (2111), the outer wall of the first connecting sleeve (214) and the water cooling groove (2111) form a sealed first water cooling channel (215), and the first mounting base (211) is provided with a first water cooling connector (216). The outgoing shaping component (22) includes a steering reflector (221). A first receiving groove (112) is provided on the outer side wall of the mirror assembly housing (1). The steering reflector (221) is located in the first receiving groove (112). The mirror assembly housing (1) is bolted with a clamping plate (222). The clamping plate (222) seals and clamps the steering reflector (221). The upper cover (12) of the mirror housing (1) is connected to a mirror base (224) via an adjusting member (23). The adjusting member (23) is used to adjust the angle of the mirror base (224). The mirror base (224) is equipped with an adjusting reflector (226). The mirror housing (1) is provided with a first temperature sensor (223) for monitoring the temperature of the steering reflector (221), and the mirror mount (224) is provided with a second temperature sensor (225) for monitoring the temperature of the regulating reflector (226).

2. The gas-tight detection based optical shaping module of claim 1, wherein: The first connecting sleeve (214) is sealed with a fixing sleeve (2112) at one end away from the second abutting sleeve (2114). The first mounting base (211) is threaded with a third abutting sleeve (2113) at one end away from the first abutting sleeve (212). The third abutting sleeve (2113) presses against the fixing sleeve (2112), so that the fixing sleeve (2112) presses against the first connecting sleeve (214).

3. The gas-tight detection based optical shaping module of claim 1, wherein: The mirror mount (224) is provided with a second water-cooling channel (2245), the mirror mount (224) is provided with a second water-cooling connector (227), the upper cover (12) of the mirror assembly housing (1) is provided with a wiring channel (1212), the upper cover (12) of the mirror assembly housing (1) is also provided with a third water-cooling connector (27), the air inlet connector (13) is provided on the upper cover (12) of the mirror assembly housing (1), and the upper cover (12) of the mirror assembly housing (1) is also provided with a wiring hole (251).

4. The gas-tight detection based optical shaping module of claim 1, wherein: It also includes a connector (5), on which an annular support groove (51) is provided. The protective mirror (4) is located in the annular support groove (51). A sealing gasket (52) is also provided in the annular support groove (51). Both sides of the connector (5) are hinged with buckles (53) and springs (54) are provided. The buckles (53) are connected to the springs (54). The inner wall of the lens housing (1) is provided with a second receiving groove (115), which extends to one side of the lens housing (1). The outer wall of the lens housing (1) is also provided with a snap-fit ​​groove (116), which corresponds one-to-one with the buckle (53). When the connector (5) is inserted into the second receiving groove (115) and the buckle (53) is locked into the receiving groove (116), the sealing gasket (52) abuts against the protective mirror (4) and the second receiving groove (115).

5. The gas-tight detection based optical shaping module of claim 1, wherein: The mirror housing (1) is also connected to a first dust cover (6), which is located below the protective mirror (4). The first dust cover (6) is connected to an air knife (7), the air outlet of which is located below the first dust cover (6). The air knife (7) and the first dust cover (6) are connected to a second dust cover (8), the air outlet of which is located inside the second dust cover (8). A first ventilation groove (61) is provided on the side of the first dust cover (6) opposite to the air knife (7), and a second ventilation groove (82) is provided on the side of the second dust cover (8) opposite to the air knife (7). The first ventilation groove (61) and the second ventilation groove (82) are connected.

6. The gas-tight detection based optical shaping module of claim 2, wherein: The fiber optic connector unit (3) includes a fiber optic socket (31), one end of which is inserted into the fixing sleeve (2112) and slidably connected to the first connecting sleeve (214). The fixing sleeve (2112) is coaxially rotatably connected to an adjusting sleeve (32), and the adjusting sleeve (32) is threadedly connected to one end of the fiber optic socket (31) that extends out of the fixing sleeve (2112).

7. The gas-tight detection based optical shaping module of claim 3, wherein: The upper cover (12) of the lens housing (1) is provided with at least two first mounting slots (1211), and the lens mount (224) is provided with at least two second mounting slots (2246). The first mounting slots (1211) and the second mounting slots (2246) correspond one-to-one. Fixing blocks (228) are bolted to both the first mounting slots (1211) and the second mounting slots (2246). A connecting rod (229) passes through the fixing block (228). The adjusting component (23) includes several tension springs (231), which are located in the first mounting groove (1211). The two ends of the tension springs (231) are respectively hung on the two corresponding connecting rods (229). The upper cover (12) of the lens assembly housing (1) is threaded with three adjusting bolts (232). A ball socket (2247) is provided at the corner of the top surface of the lens base (224). A sliding groove (2248) is also provided at the other two corners of the top surface of the lens base (224). Both sliding grooves (2248) are opened in the direction pointing to the ball socket (2247). The mirror mount (224) is also provided with a third mounting groove (2244) and a fourth mounting groove (2243). The second water-cooling connector (227) is installed in the third mounting groove (2244). The fourth mounting groove (2243) extends through to the side of the mirror mount (224) where the adjusting reflector (226) is located and to the top of the mirror mount (224). The fourth mounting groove (2243) is connected to the third mounting groove (2244). The lead wire of the second temperature sensor (225) extends into the fourth mounting groove (2243).

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