A method and system for independent monitoring of batch aging of square window lasers

Abstract

This invention relates to the field of laser electronics technology, specifically to a method and system for batch aging and independent monitoring of individual square-window lasers. The method includes: arranging multiple square-window lasers in layers and connecting them to a cooling system via water-cooling plates; measuring and storing the optical parameters of each laser before aging; independently powering each laser, monitoring the output optical power in real time and dynamically adjusting the drive current; collecting temperature, voltage, and current data in real time, cutting off the power supply and recording the anomaly when thresholds are exceeded; comparing the temperature data with the return water temperature and dynamically adjusting the outlet water temperature; measuring the optical power again after aging; matching the data before and after aging based on a unique identifier, calculating the attenuation rate, and sorting the lasers by grade. This invention combines batch aging with independent monitoring of individual lasers, improving production efficiency and product consistency.

Description

Technical Field

[0001] This invention relates to the field of laser electronics technology, specifically to a method and system for independent monitoring of individual square-window lasers during batch aging. Background Technology

[0002] As an important core light source device for laser measurement instruments, square window lasers require aging tests during mass production to verify the stability and reliability of their output optical power. Aging tests are a key step in ensuring the overall performance consistency of laser measurement instruments.

[0003] The existing technology has the following drawbacks: Existing solutions rely on high-precision source meters for aging tests. Although small-batch parallel testing is possible, it lacks the ability to independently monitor and protect individual lasers in real time. It is impossible to achieve closed-loop control of optical power and automatic protection against abnormalities at the individual laser level during the aging process. High-power lasers generate a lot of heat per laser, and using semiconductor cooling chips for heat dissipation is costly and difficult to achieve batch temperature control. Using small-batch laboratory aging methods and manually recording optical power data before and after aging can easily lead to data errors and make it impossible to accurately match and compare data of the same laser before and after aging, affecting the accuracy of product classification and sorting. Centralized power supply leads to frequent and unstable output of the current source, increasing the risk of overcurrent and shortening the life of the laser. Summary of the Invention

[0004] This invention provides a method and system for batch aging and independent monitoring of individual square-window lasers, aiming to provide the laser measurement instrument industry with an integrated solution that can simultaneously achieve batch aging and independent monitoring of individual lasers. Through independent power supply control, real-time multi-parameter acquisition, automatic data pairing, and hierarchical sorting, it improves the production efficiency and product consistency of core light source devices for laser measurement instruments.

[0005] To achieve the above objectives, the present invention provides the following technical solution: This invention discloses a method for batch aging and independent monitoring of individual square-window lasers, comprising: S100: Multiple square window lasers are arranged in layers, with multiple square window lasers in each layer. Each square window laser is connected to the cooling system through a water-cooled plate. S200: Before aging, optical parameters are measured for each square window laser to be aged, initial optical power data is obtained, and the data is bound and stored with the unique identification information of the square window laser. S300: Each square window laser is independently powered, and the output optical power of each square window laser is monitored in real time during the aging process. The driving current is dynamically adjusted according to the difference between the monitored output optical power and the target optical power. S400: During the aging process, the temperature, voltage and current data of each square window laser are collected in real time. When any parameter exceeds the preset threshold, the power supply to the corresponding square window laser is cut off and the abnormal event is recorded. S500: Compares the temperature data of the lasers in each window with the return water temperature of the cooling system, and dynamically adjusts the outlet water temperature of the cooling system based on the comparison results; S600: After aging is completed, the optical parameters of each square window laser are measured again to obtain the optical power data after aging. S700: Based on the unique identification information, the optical power data of the same square window laser before and after aging are matched and compared to calculate the optical power attenuation rate. The square window lasers are then classified and sorted according to the attenuation rate.

[0006] As a preferred embodiment of the present invention, the water-cooled plate is a corrugated metal plate structure made of high-purity aluminum.

[0007] As a preferred embodiment of the present invention, the measurement of optical parameters for each square-window laser to be aged specifically includes: A square-window laser is placed in an optical testing device, which includes an integrating sphere. Start the square window laser and collect the light emitted by the square window laser through the integrating sphere; The optical signal inside the integrating sphere is converted into an electrical signal using a photoelectric sensor; The electrical signal is calculated by combining it with the compensation amount obtained in advance through calibration with a standard light source to obtain calibrated optical power data.

[0008] As a preferred embodiment of the present invention, the inner wall of the integrating sphere is coated with a white diffuse reflective material.

[0009] As a preferred embodiment of the present invention, the independent power supply for each square-window laser specifically includes: Each square-window laser is equipped with an independent control unit; The control unit provides an independent, adjustable power supply to the corresponding square-window laser. The output optical power of the corresponding square window laser is monitored in real time by the control unit. Based on the difference between the monitored optical power and the target optical power, the output current of the adjustable power supply is adjusted by the control unit; The control unit collects temperature, voltage, and current data of the corresponding square-window laser and uploads the collected data to the main control unit.

[0010] As a preferred embodiment of the present invention, the step of dynamically adjusting the driving current based on the difference between the monitored output optical power and the target optical power specifically includes: When the monitored output optical power is lower than the target optical power, increase the drive current; When the monitored output optical power is higher than the target optical power, the drive current is reduced.

[0011] As a preferred embodiment of the present invention, the preset thresholds include a temperature upper limit threshold, a current upper limit threshold, and a voltage upper limit threshold; When the temperature of the square window laser exceeds the upper limit threshold, or the current exceeds the upper limit threshold, or the voltage exceeds the upper limit threshold, the power supply to the corresponding square window laser is cut off, and the abnormality type, abnormal time, and laser identification information are recorded in the database.

[0012] As a preferred embodiment of the present invention, the step of comparing the temperature data of the square window laser with the return water temperature of the cooling system, and dynamically adjusting the outlet water temperature of the cooling system based on the comparison result, specifically includes: The main control unit receives temperature data from each of the laser windows and obtains the return water temperature of the cooling system; Calculate the temperature difference between the laser temperature data of each window and the return water temperature; When the temperature difference exceeds the preset range, a temperature adjustment command is sent to the cooling system to adjust the outlet water temperature setting of the cooling system.

[0013] As a preferred embodiment of the present invention, the cooling system is a constant temperature chiller. The main control unit is connected to the constant temperature chiller through a communication interface to obtain the return water temperature of the constant temperature chiller in real time and send the outlet water temperature set value to the constant temperature chiller.

[0014] This invention also proposes a batch aging monitoring system for square window lasers with independent monitoring of individual lasers, comprising: The layered arrangement module is used to arrange multiple square window lasers in layers, with multiple square window lasers set in each layer, and each square window laser is connected to the cooling system through a water-cooled plate. The initial testing module is used to measure the optical parameters of each square-window laser to be aged before aging, obtain the initial optical power data, and bind and store it with the unique identification information of the square-window laser. The power supply current regulation module is used to independently power each square window laser. During the aging process, it monitors the output optical power of each square window laser in real time and dynamically adjusts the drive current based on the difference between the monitored output optical power and the target optical power. The data acquisition and protection module is used to collect temperature, voltage and current data of each square window laser in real time during the aging process. When any parameter exceeds the preset threshold, the power supply of the corresponding square window laser is cut off and the abnormal event is recorded. The temperature control module is used to compare the temperature data of the lasers in each window with the return water temperature of the cooling system, and dynamically adjust the outlet water temperature of the cooling system based on the comparison results. The retest module is used to measure the optical parameters of each square window laser again after aging is completed, and to obtain the optical power data after aging. The grading and sorting module is used to pair and compare the optical power data of the same square window laser before and after aging based on the unique identification information, calculate the optical power attenuation rate, and grade and sort the square window lasers according to the attenuation rate.

[0015] The beneficial effects of this invention are: 1. This invention employs a layered architecture combining large-area, small-unit layout with independent control of each laser. By equipping each laser with an independent MCU control unit and adjustable power supply, it achieves an organic combination of batch aging of 150 lasers and independent monitoring of each individual laser. This architecture avoids the current source instability problem caused by centralized power supply, significantly improving aging efficiency while ensuring precise control and anomaly protection at the individual laser level.

[0016] 2. This invention employs a heat dissipation method combining a corrugated metal plate water-cooled plate with an industrial-grade constant-temperature chiller. A temperature management strategy that separates data acquisition and control is used to compare temperature data in real time and dynamically adjust the outlet water temperature. This solution overcomes the limitations of traditional semiconductor cooling chips in terms of single-chip heat dissipation in batch production, achieving a high-efficiency heat exchange with a heat transfer coefficient of 3000-6000 W / (m²·℃). Through the water-cooling system and dynamic temperature regulation mechanism, the uniformity of the laser surface temperature is significantly improved, keeping the laser surface temperature within a reasonable range under typical operating conditions and effectively reducing performance dispersion caused by temperature differences.

[0017] 3. This invention integrates optical measurement and aging monitoring before and after aging into a single process. It achieves automatic pairing and comparison of optical power data through unique identification information, eliminating the risk of data errors caused by manual recording. This solution can be directly applied to the quality screening of core light source devices in laser measurement instrument production lines, providing reliable data support for accurate grading and sorting based on optical power attenuation rate, and significantly improving the overall performance consistency of laser measurement instruments. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a flowchart illustrating a method for batch aging and independent monitoring of individual square-window lasers according to the present invention. Figure 2 This is a schematic diagram of the structure of a single-cell independent monitoring system for batch aging of square window lasers according to the present invention. Detailed Implementation

[0019] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0020] Example 1: As Figure 1 As shown, the present invention provides a method for batch aging and independent monitoring of individual square-window lasers, comprising: S100: Multiple square window lasers are arranged in layers, with multiple square window lasers in each layer. Each square window laser is connected to the cooling system through a water-cooled plate. Furthermore, the water-cooled plate has a corrugated metal plate structure and is made of high-purity aluminum.

[0021] Specifically, multiple square-window lasers are arranged in layers, employing a large-area, small-unit architecture. In one embodiment, 150 square-window lasers are divided into 15 layers as an aging zone, with 10 square-window lasers arranged horizontally in each layer. This architecture achieves an organic combination of batch aging and independent monitoring of individual lasers. Each square-window laser has an optical power greater than 40W and an electrical power of approximately 70W. During the aging process, when operating under a continuous high-current constant flow, the surface temperature of a single laser will rapidly rise from room temperature (25°C) to 65°C, resulting in a sudden surge in heat generation.

[0022] Each square-window laser is connected to the cooling system via a water-cooled plate. All 10 square-window lasers on each layer are mounted on the same water-cooled plate, with the plate in close contact with the heat dissipation surface of each laser. The water-cooled plate uses a corrugated metal plate structure and is made of high-purity aluminum. Compared to traditional pure copper air-cooled heat exchangers, aluminum water-cooled plates reduce costs while improving heat exchange efficiency. The water-cooled plate is composed of multiple corrugated metal plates stacked together, forming fluid channels between them. The corrugated design of the plates induces strong turbulence as the cooling water flows through these channels, significantly increasing the heat transfer area and heat transfer coefficient.

[0023] According to Fourier's law of heat conduction, heat flows from areas of higher temperature to areas of lower temperature. The amount of heat flowing in a certain direction is proportional to the temperature gradient in that direction, and its expression is: ; in, for The heat flux density vector in the direction, i.e., the heat flux density vector per unit time along the direction. The direction through which heat passes per unit area; The thermal conductivity coefficient of the medium; For temperature exist Gradient of direction; It is the direction vector.

[0024] The heat generated by the laser during operation is transferred to the water-cooled plate through thermal conductivity, and the cooling water inside the plate carries away the heat through convection. The corrugated structure causes turbulence in the cooling water, disrupting the boundary layer and increasing the convective heat transfer coefficient.

[0025] Each water-cooled plate is connected to the cooling system via inlet and outlet pipes. The cooling system uses an industrial-grade constant-temperature chiller to centrally supply cooling water to all 15 water-cooled plates. The chiller's outlet water temperature can be adjusted within the range of 5℃ to 30℃, with a temperature control accuracy of ±1℃. After flowing out of the chiller, the cooling water is distributed to the inlet pipes of each water-cooled plate through the main water supply pipeline. It flows through the corrugated channels inside the water-cooled plate, absorbing the heat generated by the laser, and then collects through the outlet pipes back to the chiller via the main return pipeline. Through the water-cooled heat dissipation system and dynamic temperature regulation mechanism, the uniformity of the laser surface temperature is significantly improved, keeping the laser surface temperature within the target range under typical operating conditions.

[0026] S200: Before aging, optical parameters are measured for each square window laser to be aged, initial optical power data is obtained, and the data is bound and stored with the unique identification information of the square window laser. Furthermore, the optical parameter measurement of each square-window laser to be aged specifically includes: A square-window laser is placed in an optical testing device, which includes an integrating sphere. Start the square window laser and collect the light emitted by the square window laser through the integrating sphere; The optical signal inside the integrating sphere is converted into an electrical signal using a photoelectric sensor; The electrical signal is calculated by combining it with the compensation amount obtained in advance through calibration with a standard light source to obtain calibrated optical power data.

[0027] Furthermore, the inner wall of the integrating sphere is coated with a white diffuse reflective material.

[0028] Specifically, before conducting aging tests on square-window lasers, it is necessary to measure the optical parameters of each square-window laser to be aged and obtain initial optical power data.

[0029] The square-window laser to be measured is placed in an optical testing device. The optical testing device includes an integrating sphere, which is a hollow sphere with its inner wall coated with a white diffuse reflective material. The white diffuse reflective material has a spectral reflectance of over 99% in the visible spectrum, effectively capturing the light emitted by the laser and causing the light to reflect multiple times within the sphere to form a uniform distribution.

[0030] The square-window laser is activated, and the light emitted by the laser enters the integrating sphere. The light emitted by the square-window laser is collected by the integrating sphere, and after multiple diffuse reflections on the inner wall of the integrating sphere, the light tends to be uniformly distributed.

[0031] A photoelectric sensor converts the optical signal within the integrating sphere into an electrical signal. The photoelectric sensor is installed at a specific location on the integrating sphere to receive the uniform optical signal within the sphere and output an electrical signal proportional to the light intensity. This electrical signal is then converted from an analog signal to a digital signal.

[0032] The electrical signal is calculated by combining it with the compensation amount obtained in advance through calibration with a standard light source to obtain calibrated optical power data.

[0033] The output of photoelectric sensors is significantly affected by temperature, requiring temperature compensation calibration to ensure measurement accuracy. Ideally, under fixed temperature conditions, the sensor's input and output values ​​satisfy a polynomial relationship: ; in, It is the sensor's output value. It is the true value of the physical quantity measured by the sensor. Polynomial coefficients , Let be the order of the polynomial.

[0034] However, in practical applications, changes in ambient temperature can cause sensor characteristics to drift, affecting the coefficients in the above formula. It will change with temperature. Therefore It is temperature The function of the sensor. Considering the effect of temperature, the input-output relationship of the sensor can be expressed as: ; in, The current temperature. These are the elements of the temperature-coefficient relationship matrix.

[0035] Represented in matrix form, let the temperature vector be... coefficient vector Sensor output vector The temperature-coefficient relationship matrix is ​​as follows: ; Then the coefficient vector The actual value measured by the sensor is: ; To solve the matrix The elements in the dataset need to be calibrated using multiple sets of known measurement data. Assume... Group calibration data, number The sensor output of the group data is The temperature is The actual value is Construct the measurement matrix and the true value vector : ; ; in, For matrix The coefficient vector is expanded column-wise. The least squares method is used to solve for it. It can be transformed into: ; Solving for the coefficient vector Then, rearranged into a matrix In actual measurement, based on the current temperature... and sensor output Through formula The true value after temperature compensation was calculated. .

[0036] For optical power measurement, specifically, calibrating laser light intensity data under a fixed current value. Compared with the actual measured values The difference between them is used as the compensation amount. ,Right now The actual light intensity after passing through the attenuator is... From this, the attenuation coefficient can be obtained. .in, The standard illumination intensity is the one used for calibration. For the actual measured light intensity, This represents the attenuation ratio of the attenuator. This is the attenuation coefficient. The attenuation coefficient is directly related to the material of the attenuator; when the attenuation coefficient is fixed, it can be converted into the actual light intensity value.

[0037] To ensure the principle of single variable during testing, the actual light intensity needs to be considered. Compensated to standard light intensity value ,therefore As a compensation variable, the conversion formula between light intensity and light power is: ,in Indicates optical power. This indicates the illuminated area. When the illuminated area is fixed, the light intensity is directly proportional to the light power.

[0038] The initial optical power data for each square-window laser is obtained using the temperature compensation calibration algorithm described above. This initial optical power data is then bound to the unique identification information of the square-window laser and stored accordingly. The unique identification information includes the laser number, production batch, and other information to ensure that the optical power data before and after aging accurately correspond to the same laser. The bound data is stored in a database as a benchmark reference value for subsequent aging effect evaluation.

[0039] S300: Each square window laser is independently powered, and the output optical power of each square window laser is monitored in real time during the aging process. The driving current is dynamically adjusted according to the difference between the monitored output optical power and the target optical power. Furthermore, the independent power supply for each square-window laser specifically includes: Each square-window laser is equipped with an independent control unit; The control unit provides an independent, adjustable power supply to the corresponding square-window laser. The output optical power of the corresponding square window laser is monitored in real time by the control unit. Based on the difference between the monitored optical power and the target optical power, the output current of the adjustable power supply is adjusted by the control unit; The control unit collects temperature, voltage, and current data of the corresponding square-window laser and uploads the collected data to the main control unit.

[0040] Furthermore, the step of dynamically adjusting the drive current based on the difference between the monitored output optical power and the target optical power specifically includes: When the monitored output optical power is lower than the target optical power, increase the drive current; When the monitored output optical power is higher than the target optical power, the drive current is reduced.

[0041] Specifically, after completing the optical parameter measurements before aging, each square-window laser is independently powered and aging tests are started.

[0042] Each square-window laser is equipped with an independent control unit. Each control unit is implemented using an MCU (Microcontroller Unit), with 10 independent MCU control units corresponding to 10 square-window lasers per layer. Each control unit operates independently without interference, avoiding frequent and unstable current source output caused by centralized power supply. The distributed independent control architecture has inherent fault isolation capabilities; an abnormality in a single control unit does not affect the normal aging of other lasers. Each control unit communicates with the main control unit via a 485 bus, using a polling mechanism to ensure communication synchronization. In the event of a communication failure, the main control unit automatically marks the corresponding laser and records the error in the log.

[0043] An independent, adjustable power supply is provided to the corresponding square-window laser via a control unit. This adjustable power supply employs a 4½-bit precision resolution current source, enabling precise control of the output current. Within the typical laser operating current range of 3-5A, the actual measurement error of the aging current output is ±15mA. Each control unit sets the initial drive current value based on the rated operating current of that laser.

[0044] During the aging process, the output optical power of the corresponding square-window laser is monitored in real time by the control unit. The system uses an integrating sphere optical tester, which senses optical energy by using a large sphere inside a smaller sphere to achieve online optical power monitoring. The photoelectric sensor in the optical test device converts the optical signal into an electrical signal, which then undergoes photoelectric conversion and analog-to-digital conversion. It communicates with the MCU through an independent address code to achieve real-time monitoring of the optical power of a single laser. The laser can be measured without being removed from the water-cooled plate.

[0045] Based on the difference between the monitored output optical power and the target optical power, the control unit dynamically adjusts the drive current. Specifically, when the monitored output optical power is lower than the target optical power, the control unit increases the drive current to compensate for the power attenuation; when the monitored output optical power is higher than the target optical power, the control unit decreases the drive current to avoid overdriving, which could lead to laser overheating or damage. The adjustment range of the drive current is calculated based on the optical power deviation, and a closed-loop feedback control method is used to stabilize the laser's output optical power near the target optical power.

[0046] Temperature, voltage, and current data for the corresponding square-window laser are collected by the control unit. Each control unit is equipped with an independent temperature acquisition module, voltage detection circuit, and current detection circuit. The temperature acquisition module uses an industrial-grade temperature acquisition module with 12 thermocouple interfaces, connecting to the control unit via RS-485 communication. The temperature measurement accuracy is 0.1℃. The minimum acquisition period for voltage detection is 10ms, with each fixture independently detecting voltage fluctuations to ensure timely detection. Current data is acquired in real time via a current sensor.

[0047] The collected data is uploaded to the main control unit. Each control unit uploads temperature, voltage, current, and optical power data to the single-layer main control unit via RS-485 communication. The single-layer main control unit then uploads the aggregated data to the upper-level management computer. The upper-level management computer centrally manages all slave units, achieving integrated remote communication, remote start / stop, and remote monitoring.

[0048] During the aging process, 10 independent MCU control units work collaboratively with a single-layer main control MCU, employing a time-sharing and task-sharing scheduling algorithm to ensure efficient resource utilization and system real-time performance. The main control MCU is responsible for global coordination, while each control unit MCU handles local tasks with high real-time requirements.

[0049] The system employs a multi-level feedback queue scheduling algorithm for task management. This algorithm manages tasks in descending order of priority through multiple ready queues: new tasks enter the highest priority queue and are scheduled using a time-slice round-robin system; if a task is not completed, it is downgraded to a lower priority queue. Longer tasks gradually gain longer time slices, and low-priority tasks that have been waiting for too long can be upgraded to avoid starvation.

[0050] Let the number of queues be ,queue The time slice is Priority is ,Task Completion time and waiting time They are respectively: ; The main control MCU runs a high-priority queue for communication protocol processing and global scheduling, while each control unit MCU is responsible for sensor data acquisition and local control in low-priority queues. This mechanism balances short-task response, long-task completion, and real-time task priority.

[0051] S400: During the aging process, the temperature, voltage and current data of each square window laser are collected in real time. When any parameter exceeds the preset threshold, the power supply to the corresponding square window laser is cut off and the abnormal event is recorded. Furthermore, the preset thresholds include a temperature upper limit threshold, a current upper limit threshold, and a voltage upper limit threshold; When the temperature of the square window laser exceeds the upper limit threshold, or the current exceeds the upper limit threshold, or the voltage exceeds the upper limit threshold, the power supply to the corresponding square window laser is cut off, and the abnormality type, abnormal time, and laser identification information are recorded in the database.

[0052] Specifically, during the aging process, it is necessary to collect temperature, voltage, and current data of each square-window laser in real time and implement multi-dimensional anomaly protection.

[0053] Temperature data acquisition is achieved through an independent industrial-grade temperature acquisition module. This module has 12 thermocouple interfaces and connects to the control unit via RS-485 communication. Temperature acquisition is implemented in an independent unitized manner, with temperature data collected independently from each of the 10 aging lasers in each layer. Temperature sensors are installed on the surface of each laser to monitor the laser's operating temperature in real time, with a temperature measurement accuracy of 0.1℃.

[0054] The temperature sensor's measurements need to be compensated using a temperature correction calibration algorithm to reduce measurement errors. After the temperature sensor is calibrated with the temperature standard source, a one-to-one calibration compensation is performed for each temperature detection point.

[0055] Given the sensor temperature, the time required for heat to transfer from the chip to the sensor can be calculated based on the laws of thermal conduction and energy conservation. Considering that the rate of heat transfer increases with temperature, the thermal conduction equation is established: in: ; in, For temperature, For time, The thermal conductivity coefficient, For specific heat capacity, For density, The heat output per unit volume of heat source per unit time. The Laplace operator for temperature, i.e. .

[0056] Using the temperature compensation calibration algorithm described in the implementation content corresponding to S200, the true temperature value measured by the sensor is , where the temperature vector coefficient matrix and sensor output vector The definition is the same as the implementation content corresponding to S200. This algorithm is used to calibrate each thermocouple in the temperature acquisition module to obtain accurate temperature data.

[0057] Voltage data acquisition is achieved through a voltage detection circuit. The minimum acquisition period for the voltage detection frequency is 10ms. Each control unit independently detects the operating voltage of its corresponding laser to ensure timely capture of voltage fluctuations.

[0058] Current data acquisition is achieved through a current sensor. The current sensor monitors the driving current flowing through the laser in real time, with acquisition accuracy matching that of a current source with a precise 4½-bit resolution.

[0059] The preset thresholds include an upper limit threshold for temperature, an upper limit threshold for current, and an upper limit threshold for voltage. The upper limit threshold for temperature is set according to the safe operating temperature of the square-window laser; in this embodiment, it is set to 65°C. In practical applications, it can be adjusted according to the specifications of different laser models. The upper limit threshold for current is set according to the rated operating current of the laser to prevent damage from overcurrent. The upper limit threshold for voltage is set according to the rated operating voltage of the laser to prevent overvoltage breakdown.

[0060] When any parameter is detected to exceed a preset threshold, the abnormal protection mechanism is immediately triggered. Specifically, when the temperature of the square window laser exceeds the upper temperature threshold, the control unit determines it as an over-temperature abnormality; when the current exceeds the upper current threshold, the control unit determines it as an over-current abnormality; and when the voltage exceeds the upper voltage threshold, the control unit determines it as an over-voltage abnormality.

[0061] Upon detecting an anomaly, the MCU control unit immediately activates the anomaly protection mechanism, cutting off the power supply to the corresponding square-window laser. The control unit quickly disconnects the current output of the laser by controlling the adjustable power supply's switching circuit, preventing the abnormal state from continuing and causing damage to the laser.

[0062] Simultaneously, the anomaly type, anomaly time, and laser identification information are recorded in the database. Anomaly types include specific causes such as over-temperature, over-flow, and over-pressure. The anomaly time records the precise moment the anomaly occurred. Laser identification information includes the laser's unique serial number, layer number, and location number. The control unit uploads the anomaly event data to the main control unit via RS-485 communication. The main control unit writes the data to the database log table, facilitating subsequent analysis of the anomaly's cause and tracing laser quality issues.

[0063] In addition, to prevent the square-window laser from burning out due to a malfunction in the chiller and lack of chilled water output during the aging process, a digitally controlled pressure gauge is installed on the main water supply line to monitor the pressure in real time. When the pipeline pressure is detected to be lower than the preset pressure threshold, it is determined to be a cooling system malfunction. The host computer immediately cuts off the power supply to all lasers and records the abnormal cooling system event.

[0064] The above-mentioned multi-dimensional anomaly protection mechanism ensures the safety of the aging process and the reliability of the laser.

[0065] S500: Compares the temperature data of the lasers in each window with the return water temperature of the cooling system, and dynamically adjusts the outlet water temperature of the cooling system based on the comparison results; Furthermore, the comparison of the temperature data of the various window lasers with the return water temperature of the cooling system, and the dynamic adjustment of the outlet water temperature of the cooling system based on the comparison results, specifically includes: The main control unit receives temperature data from each of the laser windows and obtains the return water temperature of the cooling system; Calculate the temperature difference between the laser temperature data of each window and the return water temperature; When the temperature difference exceeds the preset range, a temperature adjustment command is sent to the cooling system to adjust the outlet water temperature setting of the cooling system.

[0066] Furthermore, the cooling system is a constant temperature chiller. The main control unit is connected to the constant temperature chiller through a communication interface to obtain the return water temperature of the constant temperature chiller in real time and send the outlet water temperature set value to the constant temperature chiller.

[0067] Specifically, during the aging process, the temperature data of the lasers in each window are compared with the return water temperature of the cooling system. Based on the comparison results, the outlet water temperature of the cooling system is dynamically adjusted to achieve closed-loop temperature control.

[0068] The main control unit receives temperature data from the lasers in each window and obtains the return water temperature of the cooling system. Each control unit uploads the collected temperature data to the single-layer main control unit in real time via RS-485 communication. The single-layer main control unit aggregates the temperature data of the 10 lasers in its layer and uploads it to the host management computer. The host management computer, as the main control unit of the system, centrally manages the temperature data of all 150 lasers across 15 layers.

[0069] The cooling system uses an industrial-grade constant-temperature chiller, and the main control unit connects to the chiller via a communication interface. This communication interface uses RS-485 communication, through which the main control unit obtains the return water temperature of the chiller in real time. The return water temperature reflects the temperature change of the cooling water after absorbing heat from the laser and is an important parameter for evaluating the heat dissipation effect.

[0070] Calculate the temperature difference between the laser temperature data of each window and the return water temperature. The main control unit will then calculate the surface temperature of each laser. With chiller return water temperature Compare and calculate the temperature difference. ,in Indicates the first A laser. The temperature difference reflects the temperature gradient from the cooling water to the laser surface; the larger the difference, the worse the heat dissipation.

[0071] When the temperature difference exceeds the preset range, a temperature adjustment command is sent to the cooling system to adjust the outlet water temperature setting. The preset range is set based on the laser's operating temperature requirements and the heat exchange efficiency of the water-cooled plate. Specifically, when the temperature difference of most lasers exceeds the preset range... When the temperature exceeds the preset upper limit, it indicates that the laser surface temperature is too high, and the outlet water temperature of the chiller needs to be lowered to enhance heat dissipation; when the temperature difference is... If the temperature drops below the preset lower limit, it indicates excessive heat dissipation. The outlet water temperature of the chiller can be appropriately increased to save energy.

[0072] The main control unit sends the outlet water temperature setpoint to the chiller. The chiller's outlet water temperature can be adjusted within the range of 5℃ to 30℃, with a temperature control accuracy of ±1℃. Based on real-time temperature comparison results, the main control unit sends a new outlet water temperature setting command to the chiller via the 485 communication interface. Upon receiving the command, the chiller automatically adjusts its cooling power to bring the outlet water temperature up to the setpoint.

[0073] Temperature control employs a strategy of separating data acquisition and control. Each control unit independently acquires temperature data from its individual lasers, while the main control unit is responsible for overall temperature monitoring and cooling system scheduling. This separation strategy avoids data transmission delays and processing bottlenecks caused by centralized control, improving the real-time performance and accuracy of temperature control.

[0074] Simultaneously with the aging process, the main control unit remotely starts the chiller unit. The main control unit sends a start command to the chiller via a communication interface, ensuring that the cooling water is circulating before the laser begins aging. After the chiller starts, cooling water flows out of the chiller, is distributed through the main water supply pipeline to the inlet pipes of each layer of water-cooled plates, flows through the corrugated channels inside the water-cooled plates, absorbs the heat generated by the laser, and then collects through the outlet pipe back to the main return water pipeline, returning to the chiller.

[0075] The main control unit dynamically adjusts the chiller's outlet water temperature in real time according to operating conditions. In the early aging stage, when the laser is just starting to operate and heat generation gradually increases, the main control unit predictively lowers the outlet water temperature based on the rate of temperature increase. During the stable aging period, when the laser surface temperature tends to stabilize, the main control unit maintains the outlet water temperature at the optimal set value. In the later aging stage, or when some lasers stop working due to abnormal protection, the overall heat generation decreases, and the main control unit appropriately increases the outlet water temperature to save energy.

[0076] By employing the aforementioned temperature comparison and dynamic temperature control mechanism, the uniformity and stability of the laser surface temperature are significantly improved, meeting the temperature control requirements of aging tests, while simultaneously enhancing system stability and energy efficiency. In practical applications, the target temperature range can be adjusted according to the laser model and aging requirements.

[0077] S600: After aging is completed, the optical parameters of each square window laser are measured again to obtain the optical power data after aging. Specifically, after aging is completed, the optical parameters of each square-window laser are measured again to obtain the optical power data after aging.

[0078] Once the square-window laser has completed its predetermined aging period, the control unit stops supplying power to the laser. The aging period is set according to the laser's design life and reliability requirements, and precise control of the aging time is achieved through a batch statistical automatic timing function.

[0079] The aged square-window laser was removed from the water-cooled plate and placed in the optical testing apparatus. The same optical testing apparatus and measurement methods as the S200 were used, including integrating sphere acquisition, photoelectric sensor conversion, temperature compensation calibration algorithm, and optical power compensation algorithm. To ensure consistency of testing conditions before and after aging, the same test parameters as before aging were used, including drive current, test temperature, and integrating sphere position.

[0080] After acquiring the electrical signal through the photoelectric sensor, the same temperature compensation calibration algorithm and optical power compensation algorithm as the S200 are used to obtain the calibrated optical power data. The output of the photoelectric sensor, after temperature correction, is then processed using the formula... The actual light intensity value is calculated, and then the conversion relationship between light intensity and light power is used. Obtain optical power .

[0081] The acquired optical power data after aging is associated with and stored in relation to the unique identification information of the square-window laser. By reading the laser's unique identification information, the optical power data after aging is stored in the corresponding record of the laser in the database, ensuring that the optical power data before and after aging can be accurately matched.

[0082] To ensure consistency in testing conditions before and after aging, the optical tests after aging use the same test parameters as before aging, including drive current, test temperature, and integrating sphere position. This consistency in testing conditions ensures the comparability of optical power data before and after aging, making the calculation of optical power attenuation rate more accurate.

[0083] The integrated design of aging and optical testing reduces the frequency of manual disassembly and assembly, thereby reducing mechanical stress and testing errors in the laser caused by frequent disassembly and assembly. Simultaneously, through automated, periodic, on-demand inspection, the system can automatically measure the optical power of some lasers at specific points in the aging process, monitoring the optical power attenuation trend without waiting for the entire aging cycle to end.

[0084] S700: Based on the unique identification information, the optical power data of the same square window laser before and after aging are matched and compared to calculate the optical power attenuation rate. The square window lasers are then classified and sorted according to the attenuation rate.

[0085] Specifically, the optical power data of the same square-window laser before and after aging are compared and matched based on the unique identification information, the optical power attenuation rate is calculated, and the square-window lasers are classified and sorted according to the attenuation rate.

[0086] The main control unit reads the unique identification information of each square-window laser from the database, and retrieves the corresponding optical power data before and after aging based on this identification information. The unique identification information includes laser number, production batch, and other information to ensure the uniqueness and accuracy of data pairing.

[0087] For the i-th square-window laser, let its optical power before aging be... The optical power after aging is Calculate the optical power attenuation of the laser. and optical power attenuation rate : ; ; in, This refers to the optical power attenuation. The optical power attenuation rate reflects the degree to which the optical power of the laser decreases during the aging process.

[0088] The main control unit performs statistical analysis on the optical power attenuation rate of all lasers. Through batch statistical functions, the system automatically calculates statistical parameters such as the average, standard deviation, maximum, and minimum attenuation rates of all lasers to evaluate the stability and consistency of the entire batch of lasers.

[0089] Square-window lasers are classified and sorted based on their optical power attenuation rate. Multiple attenuation rate thresholds are set to categorize the lasers into different classes. Specifically, the attenuation rate threshold is set as follows: ,satisfy The grading criteria are as follows: when At that time, the laser was of superior quality, with low optical power attenuation and good stability; when At that time, the laser was a qualified product, and the optical power attenuation was within an acceptable range; when At that time, the laser was a defective product with a large decrease in optical power, and it could be used in low-requirement applications. when At that time, the laser was a defective product, with excessive optical power attenuation, which did not meet the usage requirements.

[0090] The main control unit generates a sorting list based on the grading results. The list includes the unique identifier of each laser, its optical power before aging, its optical power after aging, its optical power attenuation rate, and the grading result. Operators then physically sort the lasers according to the sorting list, storing or processing lasers of different grades separately.

[0091] For lasers that trigger abnormal protection during the aging process, the main control unit reads the abnormal event record from the database log table and associates information such as the abnormality type and time with the laser's optical power data. Abnormal lasers are marked separately, and even if their optical power attenuation rate is within the acceptable range, they require additional reliability assessment or are directly deemed unqualified.

[0092] By comparing optical power data before and after aging in a one-to-one, multi-dimensional manner, and combining this with a seamless collaborative scheduling and hierarchical sorting mechanism, the stability of high-power lasers and the consistency of mass production are ensured, thereby improving the overall quality level of square window lasers.

[0093] Example 2: A company manufactures square-window lasers with a single laser having an optical power of 45W and an electrical power of 75W. They need to conduct batch aging tests on the lasers to verify product reliability. The company's original aging process used a small-batch laboratory approach, relying on high-precision source meters to perform aging tests on each laser individually, manually recording the optical power data before and after aging. Due to the high heat generation of the lasers, temperature control was difficult, leading to some lasers being damaged by overheating. Furthermore, manual data recording was prone to errors, and data before and after aging could not be accurately matched, affecting the accuracy of product grading. Faced with the demands of mass production, the original solution was inefficient and could not meet the requirements. Therefore, the company adopted a batch aging system for square-window lasers with independent monitoring of each laser, as described in this invention. Figure 2As shown, it includes a layered layout module, a preliminary test module, a power supply adjustment module, a data acquisition and protection module, a temperature control adjustment module, a retest module, and a graded sorting module.

[0094] After the system was put into use, the company arranged 150 square-window lasers in a 15-layer × 10-laser configuration, with each layer connected to an industrial-grade constant-temperature chiller via a corrugated metal water-cooling plate. The initial measurement module measured the optical parameters of the 150 lasers, obtained initial optical power data through a temperature compensation calibration algorithm, and stored it with a unique identifier.

[0095] After the aging test begins, the power supply current regulation module is equipped with an independent MCU control unit for each laser, providing drive current through a 4.5-bit precision resolution current source, with an aging current output measurement error of ±15mA. During the 72-hour aging cycle, the control unit monitors the output optical power in real time, automatically increasing the drive current to compensate when the optical power decreases.

[0096] The data acquisition and protection module monitors the temperature, voltage, and current data of 150 lasers in real time, with a temperature measurement accuracy of 0.1℃ and a minimum acquisition cycle of 10ms for voltage detection. During the aging process, laser number 7 in layer 3 experienced an abnormal temperature rise to 68℃, exceeding the 65℃ threshold. The system automatically cut off the power supply to this laser and recorded the anomaly type, anomaly time, and laser number in the database. The remaining lasers continued to age normally.

[0097] The temperature control module continuously collects temperature data from each laser and compares it with the return water temperature from the chiller. The chiller outlet water temperature is adjustable within the range of 5℃ to 30℃, with a temperature control accuracy of ±1℃. The system dynamically adjusts the outlet water temperature based on the temperature comparison results, effectively improving the uniformity and stability of the laser surface temperature during batch aging.

[0098] After 72 hours of aging, the retesting module re-measured the optical parameters of the 149 qualified lasers under the same conditions as before aging. The grading and sorting module automatically matched the optical power data of each laser before and after aging based on its unique number, calculated the optical power attenuation rate, and performed grading and sorting, generating a sorting list for operators to use.

[0099] This system enables batch processing of 150 lasers for aging at a time, effectively improving the uniformity and stability of laser surface temperature during batch aging. The aging current measurement error is ±15mA, and the temperature measurement accuracy is 0.1℃. Automatic pairing ensures data accuracy, significantly improving production efficiency and product consistency.

[0100] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for independent monitoring of individual square-window lasers during batch aging, characterized in that, include: S100: Multiple square window lasers are arranged in layers, with multiple square window lasers in each layer. Each square window laser is connected to the cooling system through a water-cooled plate. S200: Before aging, optical parameters are measured for each square window laser to be aged, initial optical power data is obtained, and the data is bound and stored with the unique identification information of the square window laser. S300: Each square window laser is independently powered, and the output optical power of each square window laser is monitored in real time during the aging process. The driving current is dynamically adjusted according to the difference between the monitored output optical power and the target optical power. S400: During the aging process, the temperature, voltage and current data of each square window laser are collected in real time. When any parameter exceeds the preset threshold, the power supply to the corresponding square window laser is cut off and the abnormal event is recorded. S5 00: Compare the temperature data of the lasers in each window with the return water temperature of the cooling system, and dynamically adjust the outlet water temperature of the cooling system based on the comparison results; S600: After aging is completed, the optical parameters of each square window laser are measured again to obtain the optical power data after aging. S700: Based on the unique identification information, the optical power data of the same square window laser before and after aging are matched and compared to calculate the optical power attenuation rate. The square window lasers are then classified and sorted according to the attenuation rate.

2. The method for batch aging and independent monitoring of individual square-window lasers according to claim 1, characterized in that, The water-cooled plate is a corrugated metal plate structure made of high-purity aluminum.

3. The method for batch aging and independent monitoring of individual square-window lasers according to claim 1, characterized in that, The optical parameter measurement of each square-window laser to be aged specifically includes: A square-window laser is placed in an optical testing device, which includes an integrating sphere. Start the square window laser and collect the light emitted by the square window laser through the integrating sphere; The optical signal inside the integrating sphere is converted into an electrical signal using a photoelectric sensor; The electrical signal is calculated by combining it with the compensation amount obtained in advance through calibration with a standard light source to obtain calibrated optical power data.

4. The method for batch aging and independent monitoring of individual square-window lasers according to claim 3, characterized in that, The inner wall of the integrating sphere is coated with a white diffuse reflective material.

5. The method for independent monitoring of batch aging of square window lasers according to claim 1, characterized in that, The independent power supply for each square-window laser specifically includes: Each square-window laser is equipped with an independent control unit; The control unit provides an independent, adjustable power supply to the corresponding square-window laser. The output optical power of the corresponding square window laser is monitored in real time by the control unit. Based on the difference between the monitored optical power and the target optical power, the output current of the adjustable power supply is adjusted by the control unit; The control unit collects temperature, voltage, and current data of the corresponding square-window laser and uploads the collected data to the main control unit.

6. The method for batch aging and independent monitoring of individual square-window lasers according to claim 1, characterized in that, The dynamic adjustment of the drive current based on the difference between the monitored output optical power and the target optical power specifically includes: When the monitored output optical power is lower than the target optical power, increase the drive current; When the monitored output optical power is higher than the target optical power, the drive current is reduced.

7. The method for batch aging and independent monitoring of individual square-window lasers according to claim 1, characterized in that, The preset thresholds include a temperature upper limit threshold, a current upper limit threshold, and a voltage upper limit threshold; When the temperature of the square window laser exceeds the upper temperature threshold, the current exceeds the upper current threshold, or the voltage exceeds the upper voltage threshold, the power supply to the corresponding square window laser is cut off, and the abnormality type, abnormal time, and laser identification information are recorded in the database.

8. The method for batch aging and independent monitoring of individual square-window lasers according to claim 1, characterized in that, The process of comparing the temperature data of the various window lasers with the return water temperature of the cooling system, and dynamically adjusting the outlet water temperature of the cooling system based on the comparison results, specifically includes: The main control unit receives temperature data from each of the laser windows and obtains the return water temperature of the cooling system; Calculate the temperature difference between the laser temperature data of each window and the return water temperature; When the temperature difference exceeds the preset range, a temperature adjustment command is sent to the cooling system to adjust the outlet water temperature setting of the cooling system.

9. A method for independent monitoring of batch aging of square window lasers according to claim 8, characterized in that, The cooling system is a constant temperature chiller. The main control unit is connected to the constant temperature chiller through a communication interface to obtain the return water temperature of the constant temperature chiller in real time and send the outlet water temperature set value to the constant temperature chiller.

10. A batch aging monitoring system for square window lasers with independent monitoring of each laser, characterized in that, The system is used to execute the method for batch aging and independent monitoring of single square-window lasers according to any one of claims 1-9, including: The layered arrangement module is used to arrange multiple square window lasers in layers, with multiple square window lasers set in each layer, and each square window laser is connected to the cooling system through a water-cooled plate. The initial testing module is used to measure the optical parameters of each square-window laser to be aged before aging, obtain the initial optical power data, and bind and store it with the unique identification information of the square-window laser. The power supply current regulation module is used to independently power each square window laser. During the aging process, it monitors the output optical power of each square window laser in real time and dynamically adjusts the drive current based on the difference between the monitored output optical power and the target optical power. The data acquisition and protection module is used to collect temperature, voltage and current data of each square window laser in real time during the aging process. When any parameter exceeds the preset threshold, the power supply of the corresponding square window laser is cut off and the abnormal event is recorded. The temperature control module is used to compare the temperature data of the lasers in each window with the return water temperature of the cooling system, and dynamically adjust the outlet water temperature of the cooling system based on the comparison results. The retest module is used to measure the optical parameters of each square window laser again after aging is completed, and to obtain the optical power data after aging. The grading and sorting module is used to pair and compare the optical power data of the same square window laser before and after aging based on the unique identification information, calculate the optical power attenuation rate, and grade and sort the square window lasers according to the attenuation rate.

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