Laser conduction and protection integrated guide rod for extreme environment

Abstract

The invention discloses a laser conduction and protection integrated guide rod for an extreme environment. The guide rod comprises a single crystal sapphire guide rod body, a CVD diamond window, an external spiral micro-channel cooling structure and a multi-layer protective kit. The single crystal sapphire guide rod body is responsible for efficiently conducting laser energy, and the CVD diamond window enhances the wear resistance of the end. The spiral micro-channel cooling structure achieves active cooling through compressed gas, and the temperature of the end is kept stable. The multi-layer protective sleeve provides heat insulation and mechanical and environmental protection, and ensures the reliability of the guide rod in an extreme environment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of high-energy laser transmission and special equipment, and particularly relates to a laser transmission and protection integrated guide rod for extreme environments. BACKGROUND

[0002] In the process of eradicating battery thermal runaway by using laser intervention technology, for battery packs without preset optical interfaces, contact type guide rod coupling is the only feasible energy transmission scheme. However, the existing industrial laser transmission components (such as mechanical arm light guide arms, optical fiber jumpers, etc.) are completely designed without considering the extreme working conditions of the battery thermal runaway rescue site, and have the following serious defects:

[0003] Lack of heat management capability: when the guide rod tip contacts the 500-800℃ high-temperature battery shell, the instantaneous heat flux density can reach the order of 104W / cm2, and the existing guide rod lacks effective active cooling, which causes the end face temperature to rise sharply, causing problems such as burning of optical coating and thermal stress cracking of materials. The existing guide rod lacks effective active cooling, which causes the end face temperature to rise sharply, causing problems such as burning of optical coating and thermal stress cracking of materials.

[0004] Insufficient thermal shock resistance: when the guide rod contacts a high-temperature surface (>500℃) within 1 second from a room temperature environment (25℃), the thermal shock exceeds 475℃ / s, and ordinary optical glass (such as K9, fused quartz) has a high risk of cracking.

[0005] Low mechanical reliability: the guide rod needs to be pressed against the rough (Ra=3.2-6.3μm) and deformed battery shell with a constant pressure of 50-100N on the rescue site, and also needs to withstand mechanical arm vibration and impact. The existing guide rod end face wear resistance and overall bending strength are insufficient.

[0006] Weak environmental adaptability: fire water mist, battery electrolyte leakage (such as HF produced by LiPF6 decomposition), smoke carbon dust and other media in the fire scene can easily damage the optical surface of the guide rod or block the mechanical structure.

[0007] State sensing capability is blank: the existing guide rod cannot sense its temperature, stress state and attitude in real time, and the operation process completely depends on external sensors, which has a poor response and poor safety.

[0008] The existing technology mainly includes the following methods, but all have corresponding defects.

[0009] After comprehensive search and analysis, the related existing technology has obvious limitations:

[0010] Industrial laser welding head: although it has basic water cooling function, the design is for clean workshop environment, and the cooling efficiency is insufficient to cope with the extreme heat load in the fire scene, and it has no physical protection and state sensing capability.

[0011] Sapphire window for high temperature observation: only solves the problem of temperature resistance, without integrating the optical optimization, active cooling and mechanical protection system required for energy transmission. SUMMARY

[0012] Therefore, the application provides a laser transmission and protection integrated guide rod for extreme environment, which can meet the requirements of high-efficiency energy transmission, extreme temperature resistance, active cooling, strong protection and intelligent sensing for emergency rescue of battery thermal runaway, and aims to provide reliable, intelligent and efficient core laser transmission equipment for battery safety emergency rescue, and completely solve the hardware bottleneck of landing application of contact type laser intervention technology.

[0013] In a first aspect, a laser transmission and protection integrated guide rod for extreme environment is provided, comprising:

[0014] A single crystal sapphire guide rod body located at the central axis of the guide rod, used for transmitting laser energy;

[0015] A CVD diamond window welded to the working end of the single crystal sapphire guide rod body, used for protecting the end of the guide rod and enhancing wear resistance;

[0016] An external micro-channel cooling structure embedded in the outer surface of the single crystal sapphire guide rod body and distributed along the length direction of the guide rod, used for actively cooling the end of the guide rod;

[0017] A multi-layer protection kit wrapped around the surface of the single crystal sapphire guide rod body and the external micro-channel cooling structure, respectively;

[0018] A sensor arranged on the side of the CVD diamond window, used for monitoring the temperature, stress state and attitude of the guide rod.

[0019] Optionally, the multi-layer protection kit specifically comprises:

[0020] An inner thermal insulation buffer layer adjacent to the single crystal sapphire guide rod body, used for blocking external radiant heat;

[0021] A middle mechanical protection layer located outside the inner thermal insulation buffer layer, providing mechanical protection and allowing the guide rod to bend within a certain angle;

[0022] An outer environmental resistance layer located outside the middle mechanical protection layer, used for resisting environmental damage.

[0023] Optionally, the guide rod substrate adopts a single crystal sapphire rod, the guide rod end face adopts a diamond micro-powder polishing process, and a double-waveband anti-reflection film is plated by using ion beam assisted deposition technology.

[0024] In addition, the diameter of the single crystal sapphire guide rod body is 6-10 mm, and the thickness of the CVD diamond window is 0.3-1.0 mm.

[0025] Optionally, the external micro-channel cooling structure is provided as a continuous spiral micro-channel with a depth of 0.5 mm, a width of 0.3 mm, and a pitch of 2 mm to achieve the maximum heat exchange area-to-volume ratio while ensuring structural strength.

[0026] Optionally, the sensor includes a temperature sensor, a force sensor, and an inertial sensor, wherein the temperature sensor is a micro K-type thermocouple, the force sensor is a six-dimensional force / torque sensor with a range of 400 N and a resolution of 0.0125 N, and the inertial sensor is an integrated 6-axis IMU for real-time monitoring of acceleration and angular velocity.

[0027] Optionally, the connecting structure between the CVD diamond window and the single-crystal sapphire guide rod body includes:

[0028] A gold-tin welding layer is used to achieve welding between the sapphire and the diamond;

[0029] A glass frit stress buffer ring is provided around the welding area to absorb and disperse thermal stress and prevent interface cracking;

[0030] A protective cover is driven by a NiTi-based shape memory alloy spring and can automatically close when the end temperature is below 100℃ and automatically open after the cooling system starts to cool to protect the guide rod end;

[0031] An air curtain nozzle is provided on the port shell to divert gas from the main cooling gas flow to form a conical air curtain for continuous blowing to prevent smoke, dust, and water mist from contaminating the optical surface.

[0032] In a second aspect, a method for laser energy transmission is implemented in the laser conduction and protection integrated guide rod for extreme environments as described in any one of the first aspects, comprising the following steps:

[0033] Using the continuous spiral micro-channel in the external micro-channel cooling structure, dry compressed air or nitrogen is used as the cooling working medium, and the cooling gas flow is dynamically adjusted by a PID controller according to the feedback of the end K-type thermocouple to stabilize the operating end temperature within a safe range, ensuring the temperature stability of the guide rod end in extreme environments;

[0034] The contact force is monitored in real time by the sensor integrated in the guide rod support base, and the force control system is closed-loop controlled to maintain stable contact force between the guide rod and the target object;

[0035] Under the premise of ensuring stable end temperature and contact force, the single-crystal sapphire guide rod body conducts laser energy to the CVD diamond window;

[0036] Through the integrated sensor array, the temperature, stress state and attitude of the guide rod are monitored in real time, and the cooling flow and the attitude of the mechanical arm are dynamically adjusted according to the monitoring data;

[0037] When the sensor detects an abnormal situation, an emergency protection measure is triggered to ensure the safety of the laser energy transmission process.

[0038] Optionally, the step of utilizing the continuous spiral microchannel in the external microchannel cooling structure specifically includes establishing a temperature-flow coordination control logic, wherein according to the feedback of the end K-type thermocouple, the cooling gas flow is dynamically adjusted by a PID controller, specifically:

[0039] When the detected end temperature T is less than 60℃, the flow rate is set to 1 L / min; when 60℃≤T<80℃, the flow rate is set to 2 L / min; when T≥80℃, the flow rate is set to 5 L / min; and an alarm signal is sent to the upper computer when the temperature reaches or exceeds 80℃.

[0040] Optionally, the contact force is monitored in real time by the sensor integrated in the guide rod support base, specifically including:

[0041] The force-position solving and anti-skid control algorithm is implemented, and the algorithm calculates the contact force vector and the normal angle θ in real time. When it is detected that the normal angle θ is greater than 5°, it is determined that there is a risk of lateral slip, and the attitude of the mechanical arm is immediately adjusted to correct the angle, so as to maintain the stable contact force between the guide rod and the target object and ensure the effective transmission of laser energy.

[0042] Optionally, the temperature, stress state and attitude of the guide rod are monitored in real time by the integrated sensor array, specifically including:

[0043] The multi-sensor data fusion and safety decision model is implemented; wherein the model fuses data from temperature sensors, force sensors and inertial sensors to monitor the working state of the guide rod in real time;

[0044] When an abnormal situation such as excessive temperature, unstable contact force or abnormal attitude is detected, an emergency protection measure is automatically triggered, and the emergency protection measure at least includes adjusting the cooling system, changing the contact force or adjusting the attitude of the guide rod.

[0045] The technical scheme provided by the present application has at least the following beneficial effects:

[0046] Improve the efficiency of laser conduction: the laser conduction and protection integrated guide rod of the present application significantly improves the conduction efficiency of laser energy by adopting single crystal sapphire and CVD diamond window and optimizing the microchannel cooling structure, reduces energy loss, and ensures efficient transmission of laser energy in extreme environments.

[0047] Enhanced environmental adaptability and durability: The integrated guide rod multi-layer protective kit design includes a heat insulation buffer layer, a mechanical protection layer, and an environmental resistance layer, enabling it to work stably in extreme environments such as high temperature, high humidity, dust, strong corrosion, etc., greatly enhancing the environmental adaptability and durability of the guide rod.

[0048] Intelligent safety control: The application integrates multi-physical field sensors and intelligent control algorithms, realizing real-time monitoring of the guide rod working state, risk warning and autonomous safety decision-making, improving the safety and reliability of operation, and reducing the risk of human operation. BRIEF DESCRIPTION OF DRAWINGS

[0049] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description are only exemplary, and for those skilled in the art, other drawings can be obtained without creative labor on the basis of the provided drawings.

[0050] Figure 1 The integrated guide rod overall structure schematic diagram provided for the embodiment of the present application;

[0051] Figure 2 The micro-channel cooling system working principle diagram provided for the embodiment of the present application;

[0052] Figure 3 The guide rod end composite structure detailed enlarged view provided for the embodiment of the present application;

[0053] Figure 4 The intelligent state monitoring and safety control system block diagram provided for the embodiment of the present application.

[0054] REFERENCE NUMERALS:

[0055] 101-guide rod body, 102-CVD diamond end, 103-microchannel, 104-inner heat insulation layer, 105-middle bellow, 106-outer protective layer, 107-sensor;

[0056] 201-gold tin solder layer, 202-glass material stress buffer ring, 203-protection cover, 204-air curtain nozzle. DETAILED DESCRIPTION

[0057] In order to make the purpose, technical scheme and advantages of the present application more clear and obvious, the following will further describe the present application in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application, and are not used to limit the present application.

[0058] In the description of the present application, the terms "comprising", "having", and any variations thereof, are intended to cover a non-exclusive inclusion, for example, a process, method, system, product or apparatus that includes a list of steps or units not necessarily limited to those explicitly listed, but can also include other steps or units inherent to such processes, methods, products or apparatus, or steps or units added based on further optimization of the concept of the present application.

[0059] In the process of eradicating battery thermal runaway by laser intervention technology, for battery packs without preset optical interfaces, contact-type guide rod coupling is the only feasible energy transfer scheme. However, the existing industrial laser transmission components (such as mechanical arm light guide arms, optical fiber jumpers, etc.) are completely designed without considering the extreme working conditions of battery thermal runaway rescue sites, and have the following serious defects:

[0060] Lack of thermal management capability: when the guide rod tip contacts the 500-800℃ high-temperature battery shell, the instantaneous heat flux density can reach orders of magnitude, and the existing guide rod lacks effective active cooling, causing the end face temperature to rise sharply, causing problems such as burning of optical coatings and thermal stress cracking of materials.

[0061] Inadequate thermal shock resistance: when the guide rod contacts a high-temperature surface (>500℃) within 1 second from a room temperature environment (25℃), the thermal shock exceeds 475℃ / s, and ordinary optical glass (such as K9, fused quartz) has a high risk of cracking.

[0062] Low mechanical reliability: the guide rod on the rescue site needs to be pressed against the rough (Ra=3.2-6.3μm) and deformed battery shell with a constant pressure of 50-100N, and also needs to withstand mechanical arm vibration and impact. The existing guide rod end face wear resistance and overall bending strength are insufficient.

[0063] Weak environmental adaptability: fire water mist, battery electrolyte leakage (such as HF produced by LiPF6 decomposition), smoke carbon dust, etc. in the fire scene can easily damage the guide rod optical surface or block the mechanical structure.

[0064] State sensing capability blank: the existing guide rod cannot sense its temperature, stress state and attitude in real time, and the operation process completely depends on external sensors, with poor response and safety.

[0065] The related prior art has obvious limitations:

[0066] Industrial laser welding head: although it has basic water cooling function, the design is for clean workshop environment, and the cooling efficiency is insufficient to cope with the extreme heat load in the fire scene, and it has no physical protection and state sensing capability.

[0067] Sapphire window for high temperature observation: only solves the problem of temperature resistance, without integrating the optical optimization, active cooling and mechanical protection system required for energy transmission.

[0068] It can be seen that there is no laser conducting guide rod in the prior art that can simultaneously meet the five characteristics of high-efficiency energy transmission, extreme temperature resistance, active cooling, strong protection, and intelligent sensing required for battery thermal runaway emergency rescue.

[0069] Based on the above technical background, the present application aims to provide a laser conducting and protection integrated guide rod for extreme environments, which systematically solves all the defects of the prior art, and the specific purposes are as follows:

[0070] Building an optical core with extreme temperature resistance and thermal shock resistance: through innovative material combination and interface structure, ensure that the optical performance of the guide rod decays <1% and the structure is complete under 1000℃ environmental radiation and >500℃ / s thermal shock.

[0071] Implementing efficient active thermal management: integrating embedded micro-channel cooling system, ensuring that the temperature of the guide rod operating end is stable below 80℃ under any working condition, and eliminating thermal failure.

[0072] Providing all-round physical and chemical protection: through multi-layer composite protection kit and end protection mechanism, the guide rod can resist mechanical impact, chemical corrosion and environmental pollution in the fire scene.

[0073] Endowing intelligent state perception and autonomous protection capability: integrating multi-physical field sensors and intelligent control algorithms, realizing real-time monitoring of working state, risk warning and autonomous safety decision.

[0074] Ensuring high energy transmission efficiency and reliability: maintaining laser energy transmission efficiency >80% under extreme environments, and withstanding >1000 standard operation cycles without performance degradation.

[0075] The present application aims to provide reliable, intelligent and efficient core laser transmission equipment for battery safety emergency rescue, and completely solve the hardware bottleneck in the final stage of landing application of contact-type laser intervention technology.

[0076] The core of the present application is to redefine the "laser conducting guide rod", which is upgraded from a passive energy transmission pipeline to a high-reliability integrated system integrating energy conduction, thermal management, physical protection and intelligent sensing. The design concept is: actively defending against extreme environments, intelligently sensing to ensure operation safety, and achieving performance breakthroughs through material and structure limit design.

[0077] The present application discloses a laser conducting and protection integrated guide rod for extreme environments, comprising:

[0078] A single crystal sapphire guide rod body located on the central axis of the guide rod for conducting laser energy;

[0079] CVD diamond window, welded to the working end of the single-crystal sapphire guide rod body, for protecting the end of the guide rod and enhancing wear resistance;

[0080] External micro-channel cooling structure, embedded in the outer surface of the single-crystal sapphire guide rod body, distributed along the length direction of the guide rod, for actively cooling the end of the guide rod;

[0081] Multi-layer protective kit, respectively coated on the surface of the single-crystal sapphire guide rod body and the external micro-channel cooling structure;

[0082] Sensor, arranged on the side of the CVD diamond window, for monitoring the temperature, stress state and attitude of the guide rod.

[0083] As Figure 1 The integrated guide rod overall structure provided by the embodiment of the present application is shown in the figure, the guide rod is composed of multiple key parts, including a single-crystal sapphire guide rod body 101, which is located at the central axis of the guide rod and is responsible for conducting laser energy. A CVD diamond window 102 is welded to the working end to enhance wear resistance and protect the end of the guide rod. An external micro-channel 103 is embedded in the outer surface of the single-crystal sapphire guide rod body, distributed along the length direction of the guide rod, for actively cooling the end of the guide rod to maintain temperature stability in extreme environments.

[0084] In addition, a multi-layer protective kit is coated on the outside of the guide rod body and the micro-channel cooling structure to provide additional protection. These protective layers include an inner thermal insulation layer 104, a middle bellow 105 and an outer protective layer 106, which are respectively used for blocking external radiant heat, providing mechanical protection and resisting environmental invasion. A sensor 107 integrated on the guide rod is used to monitor the temperature, stress state and attitude of the guide rod to ensure the safety and reliability of the laser energy transmission process. The whole design aims to achieve efficient energy transmission, active thermal management, all-round physical protection and intelligent state monitoring to adapt to laser intervention applications in extreme environments.

[0085] The system architecture of the guide rod in the present application is composed of four subsystems in cooperation:

[0086] Optical conduction core subsystem: establish a low-loss and high-damage-resistant laser transmission channel.

[0087] Active thermal management subsystem: cope with extreme thermal load and maintain a constant temperature working environment for the optical core.

[0088] Multi-level physical protection subsystem: resist external mechanical, chemical and environmental invasion.

[0089] Intelligent state monitoring and safety control subsystem: realize real-time sensing, decision-making and execution to ensure system safety.

[0090] I. Optical conduction core subsystem

[0091] The design goal of this subsystem is to achieve the highest energy flux and longest service life under extreme operating conditions.

[0092] (1) Limit selection and justification of guide rod substrate

[0093] Material: C-axis <0001> oriented single-crystal sapphire with a diameter of Φ8.0+0 / -0.005mm. (Good, the selection criteria are as follows:)

[0094] Optical performance: Bulk absorption coefficient at 1064nm wavelength < It is far lower than that of ordinary optical glass ( This reduces heat deposition.

[0095] Thermodynamic properties: thermal conductivity @25℃ (60 times that of fused silica), reducing the lateral temperature gradient; coefficient of thermal expansion It has good thermal shock resistance.

[0096] Mechanical properties: Knoop hardness It has a compressive strength of 2.0 GPa and can withstand huge contact pressure.

[0097] Precision optical processing: The end face of the guide rod is polished with diamond micro powder, with a surface accuracy of λ / 10@633nm and a surface roughness Ra<0.3nm; a dual-band antireflection coating of 1064nm & 2940nm is deposited using ion beam assisted deposition technology, with the coating adhesion reaching ASTM D3359 standard 5B level and a single-sided residual reflectivity of <0.1%.

[0098] (2) End interface reinforcement structure

[0099] Functional requirements: To solve the problems of abrasive wear, adhesive wear and thermal shock failure when the end face of the guide rod is in direct contact with high temperature and rough battery casing.

[0100] Solution:

[0101] CVD diamond window: Φ10mm×0.5mm optical-grade CVD diamond sheet is used, with thermal conductivity > ,hardness .

[0102] Highly reliable welding process: Using Au80Sn20 eutectic solder, sapphire and diamond are welded in a hydrogen-protected brazing furnace at 320℃, resulting in a weld layer with good airtightness, high strength, and extremely low thermal resistance.

[0103] Stress buffer transition zone: A ring-shaped phosphate-based glass seal is designed around the weld zone, with a thermal expansion coefficient of [missing information]. , between sapphire ( ) and diamond ( ), absorbs and disperses thermal stress, prevents interface cracking.

[0104] II. Active thermal management subsystem

[0105] The core task of this subsystem is to solve the problem of kilowatt-level instantaneous heat dissipation.

[0106] The embedded micro-channel cooling structure design includes the use of ultrasonic precision machining technology on the outer surface of the sapphire guide rod to manufacture continuous spiral micro-channels with a depth of 0.5mm, a width of 0.3mm, and a pitch of 2mm, achieving the maximum heat exchange area / volume ratio while ensuring structural strength.

[0107] Cooling medium and system medium selection: compressed dry air or nitrogen is used to avoid the risk of leakage and pollution and freezing of liquid cooling, and to adapt to the fire scene.

[0108] Cooling system: composed of air compressor, gas tank, vortex tube refrigerator, and precision mass flow controller, the vortex tube can separate 0.7MPa compressed air into 5℃ cold gas stream and 80℃ hot gas stream.

[0109] Intelligent temperature control strategy: according to the feedback of the K-type thermocouple at the end, the cooling gas flow (1-5 L / min) is dynamically adjusted by the PID controller to stabilize the temperature at the working end below 80℃; facing an initial contact temperature of 500℃, the end temperature can be pulled back to the safe range within 3 seconds.

[0110] As Figure 2 The working principle diagram of the micro-channel cooling system is given, the system starts with a compressed gas source, which provides the necessary cold gas stream for the vortex tube refrigerator. The vortex tube refrigerator uses compressed air to generate cold gas stream and hot gas stream, of which the cold gas stream is directed to the mass flow controller. The end thermocouple is responsible for monitoring the temperature of the guide rod end and feeding back the temperature to the PID controller. The PID controller adjusts the mass flow controller according to the received temperature feedback signal to control the cooling gas flow through the guide rod spiral micro-channel, ensuring that the end temperature is maintained within the safe working range.

[0111] The cooling gas adjusted by the mass flow controller flows through the guide rod spiral micro-channel and exchanges heat with the guide rod, carrying away the heat generated by laser conduction. The heat-exchanged gas carries heat out of the system. The entire cooling process is a closed-loop control system, which dynamically adjusts the cooling gas flow through the PID controller to adapt to different heat loads and environmental conditions, ensuring the stable operation of the guide rod in extreme environments.

[0112] III. Multi-level physical protection subsystem

[0113] This subsystem provides protection for the optical core, ensuring its stable operation at the rescue site.

[0114] The three-layer composite protection kit includes:

[0115] The inner heat-insulating buffer layer is made of high-purity alumina polycrystalline fiber braided sleeve, with a long-term use temperature > 1200°C and a thermal conductivity coefficient < 0.5 W / m·K at 1000°C. It blocks external radiant heat.

[0116] The middle mechanical protection layer is made of 316L stainless steel single-layer corrugated pipe, providing IP67 level sealing protection and allowing the guide rod to bend ±15° to adapt to uneven battery pack surfaces.

[0117] The outer environmental resistance layer is made of flame-retardant silicone rubber coating, meeting the UL94 V-0 flame retardant standard, with excellent acid and alkali corrosion resistance and aging resistance.

[0118] The end active protection mechanism includes:

[0119] The normally closed protective cover is driven by a NiTi-based shape memory alloy spring, which contracts when the end temperature is below 100°C, causing the silicon carbide ceramic protective cover to close. After the cooling system is started and cooled down, the spring is heated and elongated, causing the protective cover to automatically open.

[0120] The continuous air curtain protection diverts 0.5 L / min of gas from the main cooling airflow, forming a conical air curtain through a micro-nozzle array at the end, continuously blowing to prevent smoke, dust, and water mist from contaminating the optical surface.

[0121] As Figure 3 The detailed enlarged view of the guide rod end composite structure is given. The working end of the single-crystal sapphire guide rod body 101 is welded with a CVD diamond window 102, which enhances the wear resistance and protection performance of the end. Between the CVD diamond window and the sapphire guide rod body, a gold-tin solder layer 201 is used to achieve high-reliability welding, and a glass material stress buffer ring 202 is located outside the welding area to absorb thermal stress and prevent interface cracking, ensuring the stability and durability of the structure.

[0122] In addition, there is a protective cover 203 driven by a shape memory alloy spring, which can automatically close when the end temperature is below 100°C, protecting the guide rod end from environmental damage. After the cooling system is started and cooled down, the protective cover will automatically open for laser conduction. The air curtain nozzle 204 is located on the port shell to divert gas from the main cooling airflow, forming a conical air curtain to continuously blow the guide rod end, preventing smoke, dust, and water mist from contaminating the optical surface, thereby ensuring the clarity and efficiency of laser conduction.

[0123] IV. Intelligent Status Monitoring and Safety Control Subsystem

[0124] This subsystem is the intelligent core of the guide rod, enabling the leap from tool to intelligent equipment. Specifically, it includes:

[0125] Multiphysics sensor array:

[0126] End-point status monitoring: Miniature K-type thermocouples are directly welded to the edge of the diamond window, with a response time of <100ms.

[0127] Force sensing: The guide rod support base integrates a six-dimensional force / torque sensor with a range Fz: 400N and a resolution of 0.0125N.

[0128] Motion and attitude sensing: Integrated 6-axis IMU for real-time monitoring of acceleration (±16g) and angular velocity (±2000° / s).

[0129] Security control logic and algorithms:

[0130] Heat-flow coordinated control: Establish a "temperature-flow" lookup table model. When T < 60℃, the flow rate is 1L / min; when 60℃ ≤ T < 80℃, the flow rate is 2L / min; when T ≥ 80℃, the flow rate is 5L / min, and an alarm is sent to the host computer.

[0131] Force-position calculation and anti-slip control: The contact force vector and the angle θ between the normal and the contact force vector are calculated in real time. When θ > 5°, it is determined that there is a risk of lateral slippage, and the angle is corrected immediately by fine-tuning the posture of the robotic arm.

[0132] Collision warning and protection: By integrating IMU and force sensor data, when abnormal high-frequency vibration or impact torque is detected, an emergency retraction procedure is triggered to avoid equipment damage.

[0133] The following describes the system integration and workflow of the above subsystems:

[0134] The integrated interface uses a standard SMA905 fiber optic interface at the tail of the guide rod for laser input, and integrates an aviation plug for quick connection of power, sensor signals and cooling gas.

[0135] Typical workflows include:

[0136] Standby state: Protective cover closed, cooling system operating at low flow rate (1 L / min).

[0137] Approach and Positioning: The robotic arm moves the guide rod to approach the target, the ToF sensor assists in positioning, and the protective cover remains closed.

[0138] Docking preparation: When the end of the guide rod is about 10mm away from the target, the cooling system is increased to the pre-working flow rate (2 L / min), the protective cover is opened, and the air curtain is activated.

[0139] Contact and Coupling: The robotic arm pushes the guide rod to contact the housing in a controlled force mode, and the force sensor ensures that the contact force is stable at 70±3 N.

[0140] Laser intervention: Once all safety conditions (force, temperature, attitude) are met, the laser is enabled and energy transfer begins.

[0141] Process monitoring and adjustment: Real-time monitoring of sensor data to dynamically adjust cooling flow and robotic arm posture.

[0142] Intervention End and Removal: The laser stops, the cooling system continues to run until the tip temperature is < 50℃, the protective cover is closed, and the guide rod is removed.

[0143] like Figure 4 A block diagram of an intelligent state monitoring and safety control system is presented. The system consists of a perception layer, a decision layer, and an execution layer, forming a closed-loop control system. The perception layer includes a multi-sensor array, such as temperature sensors (thermocouples), force sensors (six-dimensional force / torque sensors), and attitude sensors (6-axis IMU). These sensors are responsible for collecting raw data of the guide rod, including temperature, force state, and attitude information.

[0144] The decision-making layer, comprised of a central processing unit and intelligent algorithms, is responsible for data fusion and state calculation, as well as the execution of safety control logic and algorithm libraries. This layer analyzes data from the perception layer to determine whether the laser enabling conditions are met. If not, it maintains a safe standby state; if so, it issues instructions to execute actions. The execution layer includes actuators such as the robotic arm control system, cooling system mass flow controller, and laser power supply and control. These mechanisms receive instructions from the decision-making layer and modify contact force and attitude, end-effector thermal state, or inject laser energy to achieve precise control and safe operation of the guide rod.

[0145] The key innovations of this application include:

[0146] Breakthrough in Materials and Interface Science: The first "single-crystal sapphire-CVD diamond" composite optical tip solves the global challenge of highly reliable bonding between high-hardness, high-thermal-conductivity, and high-transmittance materials through a composite interface process of gold-tin eutectic bonding and glass stress buffering.

[0147] Thermal management technology innovation: For the first time, a spiral microchannel with an aspect ratio >1.5:1 was precisely and non-destructively machined on brittle single-crystal sapphire, and a highly efficient active cooling system based on gaseous working fluid was constructed, improving thermal management capabilities by an order of magnitude.

[0148] Deep integration of intelligence: Upgrade the guide rod into an intelligent terminal with multi-sensor fusion perception, model predictive control and safe autonomous decision-making, defining the next generation of special laser transmission equipment standards.

[0149] System-level protection design: It proposes a three-layer protection kit of "thermal insulation-mechanical-environment" and an active protection mechanism of "shape memory alloy protective cover + air curtain" to form a defense-in-depth system and ensure survivability in complex fire environments.

[0150] Table 1 below provides a summary of key performance data.

[0151] Table 1 Summary of Key Performance Data

[0152]

[0153] The following are specific examples of optional implementations:

[0154] Example 1: Continuous intervention in high-temperature deep-seated fires at energy storage power stations

[0155] (1) Test scenario

[0156] Inside a 100kWh energy storage container, a lithium iron phosphate module experienced deep thermal runaway due to overcharging, with the internal temperature exceeding 800°C. The pressure relief valve emitted a column of thick smoke and fire, and traditional gas extinguishing methods proved ineffective.

[0157] (2) Implementation process

[0158] System deployment: The tracked firefighting robot equipped with the guide rod of this application enters the cabin, where the ambient temperature is 150℃.

[0159] Target location: The infrared sensor at the front end of the guide rod identifies the hot spot temperature of the faulty module housing, which reaches 650℃.

[0160] Active cooling start-up: When 200mm away from the target, the cooling nitrogen flow rate is increased to 4L / min, and the end temperature drops from 85℃ to 45℃.

[0161] Contact coupling: The robotic arm applies a constant force of 75N to press the guide rod tightly against the side of the module. The temperature rises sharply to 220℃ at the moment of contact and is suppressed back to 75℃ within 1.2 seconds.

[0162] Laser intervention: 1064nm pulsed laser (single pulse energy 800mJ, repetition frequency 15Hz) is emitted and the intervention is continued for 8 seconds (120 pulses).

[0163] Process monitoring: Contact force fluctuation ±2N, guide rod posture stable, LIBS spectroscopy shows that the electrolyte characteristic peak decays by more than 90% within 300ms.

[0164] (3) Implementation results

[0165] The open flame is extinguished within 5 seconds, and the module surface temperature drops from 650℃ to 95℃ within 30 seconds; the wear of the diamond tip of the guide rod is only 0.3μm, and the optical performance is not degraded. Compared with traditional water mist fire extinguishing, the efficiency is greatly improved and reignition is prevented.

[0166] Example 2: Firefighting at the Bottom of an Electric Vehicle Battery Pack in a Tunnel

[0167] (1) Special working conditions

[0168] The bottom of the battery pack of the vehicle involved in the accident was close to the ground, in a narrow space, with electrolyte and fire-fighting water flowing on the ground.

[0169] (2) Implementation points

[0170] Adaptive adjustment: The guide rod is cut into the bottom of the battery pack at a 15° angle to the horizontal plane, and the corrugated tube is used to flexibly adapt to the confined space.

[0171] Environmental protection: The outer silicone protective sleeve resists corrosion from electrolyte with pH≈2, and the air curtain system prevents water accumulation and splashing of dirt.

[0172] Force control accuracy: On bumpy ground, the force control system compensates for the vibration of the robotic arm, and the standard deviation of the contact force is kept within ±1.5N.

[0173] (3) Performance data

[0174] From robot positioning to completing intervention at 3 points, the total time was 2 minutes and 15 seconds; the guide rod worked in a corrosive environment for more than 10 minutes, and the optical performance of the end face remained unchanged.

[0175] Example 3: Adaptability verification for emergency rescue in high-altitude and cold environments

[0176] (1) Test conditions

[0177] In a -25℃ low-temperature experimental chamber, an electric vehicle fire was simulated during a northern winter.

[0178] (2) Special measures and performance

[0179] Low-temperature start-up: The cooling gas pipeline is equipped with an electric heat tracing system to prevent freezing and ensure normal cooling of the vortex tube.

[0180] Material properties: The silicone jacket remains flexible at low temperatures without becoming brittle or cracking.

[0181] Sensor reliability: All sensors are working properly, and the thermocouple temperature measurement error is <±1.5℃.

[0182] (3) Verification results

[0183] The system's response time and energy transfer efficiency decrease by less than 3% at extreme low temperatures compared to normal temperature conditions, enabling it to operate in all climates.

[0184] The technical effects (data support and mechanism analysis) of this application specifically include:

[0185] (1) Energy transfer stability under extreme conditions

[0186] Actual test data: After working continuously for 10 minutes under ambient radiation at 1000℃, the transmittance of the guide rod to 1064nm laser decreased from 99.5% to 99.2%, and the attenuation was negligible.

[0187] Mechanism analysis: The extremely low intrinsic absorption of the sapphire substrate and the active cooling system suppress the thermally induced absorption effect, while the forced convection heat transfer in the microchannels removes heat in a timely manner, maintaining the stability of optical constants.

[0188] (2) Exceptional thermal shock resistance and durability

[0189] Actual test data: In the 25℃←→500℃ water quenching thermal shock test, the guide rod end showed no cracks after 1200 cycles, and its optical performance remained intact.

[0190] Mechanism analysis: In the "sapphire-diamond" composite structure, the high thermal conductivity of diamond diffuses surface heat, and the annular glass sealing ring absorbs interfacial stress, preventing fatigue fracture of brittle materials.

[0191] (3) Precise force-thermal coupling control and intelligent protection

[0192] Actual test data: During the simulated rescue, four lateral slip risks were successfully avoided with early warning, and the contact force control accuracy was within ±3N throughout the entire process.

[0193] Mechanism analysis: The multi-sensor fusion algorithm calculates force and IMU data, and achieves millinewton-meter level torque compensation through feedforward-feedback composite control, enabling precise contact.

[0194] (4) Comprehensive environmental adaptability and long service life

[0195] Actual test data: After 500 standard operating cycles, the overall performance degradation is less than 2%, and the expected service life is over 2000 hours.

[0196] Mechanism analysis: Layered protection design addresses different failure modes in a targeted manner, achieving a synergistic improvement in system reliability.

[0197] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0198] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A laser conduction and protection integrated guide rod for extreme environments, characterized in that, include: The single-crystal sapphire guide rod body is located on the central axis of the guide rod and is used to conduct laser energy; CVD diamond window, welded to the working end of the single crystal sapphire guide rod body, is used to protect the end of the guide rod and enhance wear resistance; An external microchannel cooling structure is embedded in the outer surface of the single-crystal sapphire guide rod body and distributed along the length of the guide rod for active cooling of the guide rod end; A multi-layered protective kit is respectively wrapped around the surface of the single-crystal sapphire guide rod body and the external microchannel cooling structure; The sensor, located on the side of the CVD diamond window, is used to monitor the temperature, stress state, and attitude of the guide rod.

2. The laser conduction and protection integrated guide rod for extreme environments according to claim 1, characterized in that, The multi-layered protection kit specifically includes: The inner heat insulation buffer layer, which is adjacent to the monocrystalline sapphire conductor body, is used to block external radiant heat. The middle mechanical protection layer, located outside the inner thermal insulation buffer layer, provides mechanical protection and allows the guide rod to bend within a certain angle; The outer environmental protection layer, located outside the middle mechanical protection layer, is used to protect against environmental damage.

3. The laser conduction and protection integrated guide rod for extreme environments according to claim 1, characterized in that, The guide rod substrate is made of single-crystal sapphire rod, the end face of the guide rod is polished with diamond micro powder, and a dual-band antireflection film is deposited using ion beam assisted deposition technology. In addition, the diameter of the single-crystal sapphire guide body is 6-10mm, and the thickness of the CVD diamond window is 0.3-1.0mm.

4. The laser conduction and protection integrated guide rod for extreme environments according to claim 1, characterized in that, The external microchannel cooling structure is configured as a continuous spiral microchannel with a depth of 0.5 mm, a width of 0.3 mm, and a pitch of 2 mm, in order to achieve the maximum heat exchange area to volume ratio while ensuring structural strength.

5. The laser conduction and protection integrated guide rod for extreme environments according to claim 1, characterized in that, The sensors include a temperature sensor, a force sensor, and an inertial sensor. The temperature sensor is a miniature K-type thermocouple, the force sensor is a six-dimensional force / torque sensor with a range of 400N and a resolution of 0.0125N, and the inertial sensor is an integrated 6-axis IMU used for real-time monitoring of acceleration and angular velocity.

6. The laser conduction and protection integrated guide rod for extreme environments according to claim 1, characterized in that, The connection structure between the CVD diamond window and the single-crystal sapphire guide body includes: A gold-tin solder layer is used to weld sapphire and diamond together; A glass stress buffer ring is placed around the welding area to absorb and disperse thermal stress and prevent interface cracking. The protective cover, driven by a NiTi-based shape memory alloy spring, can automatically close when the end temperature is below 100°C and automatically open after the cooling system is activated to protect the end of the guide rod. Air curtain nozzles, located on the port housing, are used to divert gas from the main cooling airflow to form a cone-shaped air curtain, which continuously blows to prevent smoke, dust and water mist from contaminating the optical surface.

7. A method for laser energy transfer, implemented using the laser conduction and protection integrated guide rod for extreme environments as described in any one of claims 1 to 6, characterized in that, Includes the following steps: By utilizing the continuous spiral microchannels in the external microchannel cooling structure, compressed dry air or nitrogen is used as the cooling medium. Based on the feedback from the K-type thermocouple at the end, the cooling gas flow rate is dynamically adjusted by a PID controller to stably control the working end temperature within a safe range, ensuring the temperature stability of the guide rod end in extreme environments. The contact force is monitored in real time by a sensor integrated into the guide rod support base, and a closed-loop force control system is used to maintain a stable contact force between the guide rod and the target object. Under the premise of ensuring stable end temperature and contact force, laser energy is conducted to the CVD diamond window through the single crystal sapphire guide rod body; The integrated sensor array monitors the temperature, stress state, and attitude of the guide rod in real time, and dynamically adjusts the cooling flow and robotic arm attitude based on the monitoring data. When the sensor detects an abnormality, it triggers emergency protection measures to ensure the safety of the laser energy transfer process.

8. The laser energy transfer method according to claim 7, characterized in that, The steps for utilizing the continuous spiral microchannels in an external microchannel cooling structure specifically include establishing a temperature-flow coordinated control logic. This logic involves dynamically adjusting the cooling gas flow rate using a PID controller based on feedback from the K-type thermocouple at the end. Specifically: When the detected end temperature T is less than 60℃, the flow rate is set to 1 L / min; when 60℃≤T<80℃, the flow rate is set to 2 L / min; when T≥80℃, the flow rate is set to 5 L / min; and an alarm signal is sent to the host computer when the temperature reaches or exceeds 80℃.

9. The laser energy transfer method according to claim 7, characterized in that, Contact force is monitored in real time by sensors integrated into the guide rod support base, specifically including: The algorithm implements force-position calculation and anti-slip control. The algorithm calculates the contact force vector and the normal angle θ in real time. When the normal angle θ is detected to be greater than 5°, it determines that there is a risk of lateral slippage and immediately corrects the angle by fine-tuning the attitude of the robotic arm to maintain a stable contact force between the guide rod and the target object, ensuring the effective transfer of laser energy.

10. The laser energy transfer method according to claim 7, characterized in that, The guide rod's temperature, stress state, and attitude are monitored in real time through an integrated sensor array, specifically including: Implement a multi-sensor data fusion and safety decision model; the model integrates data from temperature sensors, force sensors, and inertial sensors to monitor the working status of the guide rod in real time; When an abnormal situation is detected, such as excessively high temperature, unstable contact force, or abnormal posture, emergency protection measures are automatically triggered. Emergency protection measures include at least adjusting the cooling system, changing the contact force, or adjusting the guide rod posture.

Images