Handheld laser system

Abstract

A handheld laser system. In certain examples the handheld laser system includes a laser source emitting laser light at a wavelength for performing a material processing operation on a workpiece materi

Description

This application claims the benefit of U.S. Provisional Patent Application No. 5 63 / 069,816 filed on August 25, 2020, and to U.S. Provisional Patent Application No. 63 / 089,113 filed on October 8, 2020, each of which is heroin incorporated by reference in its entirety. background 10 Tcghnigal Field The technical field relates generally to a handheld laser device that can be wed for material processing operations, and more specifically to a handheld laser device configured with a plasma sensor. 15 Backgroup^ Discussion The use of lasers in material processing applications has increased over the last four decades and is becoming increasingly important in modem maaufaeDriug processes. Lasers are used in a variety of applications, including welding, cutting, drilling, surface hardening, and additive manufacturing. Fiber lasers in particular offer several advantages over other 20 laser technologies, such as excimer or COa systems. For example, fiber laser technology provides lower maintenance costs by eliminating downtime, reducing the spares inventory, decreasing the cost of processing gas and electricity, and in many instances lowering labor costs associated with keeping older types of lasers operational. Besides a lower cost of ownership, fiber laser technology also offers high wall plug efficiencies, long diode lifetimes, 25 minimal maintenance, and versatility since the same unit can often cut, weld, or drill. Because of their physical size, the fiber laser can also be easily transported. In addition, they offer low beam divergence and do not require warm-up since there is no spot size change with power, and possess a large dynamic range. Handheld laser devices have up until now have been used in low power applications, 30 including medical devices and diagnostic instrumentation. While hsgher power lasers (e.g., at least 1 kW) have been conventionally used for industrial cutting and welding in the industrial community, these systems have typically been too expensive for many smaller machine shops or other smaller-scaie end users. However, over time the average power of laser diodes has in some aspects, the control command tens off power to the laser source when the optical intensity value is lower than the threshold value, and maintains power to the laser source when fee optical intensity value is at or greater than the threshold value. In further aspects, the predetermined time period is at least 100 microseconds (us). 5 In some aspects, the handheld laser system further includes at least one optical filter configured io block light at the wavelength of the emitted laser light from reaching the plasma sensor. In some aspects, the handheld laser system further includes an air-cooling system coupled to the laser source for dissipating heat. 10 In further aspects, the handheld laser system further includes a laser module feat houses the laser source, fee air-cooling system, and the controller. In further aspects, the laser module is configured to be mounted to a movable cart. In some aspects, the handheld laser system further includes a housing configured as a handheld apparatus having rm outlet for the laser beam. 15 In further aspects, the handheld laser system further includes at least one movable minor positioned within the housing, fee at least one movable miner configured to wobble the laser beam. In farther aspects, the handheld apparatus is of one-psece construction. In further aspects, the handheld apparatus is configured wife a modular attachment 20 system for a nozzle. In further aspects, the handheld apparatus is configured to be gas-cooled. In further aspects, the handheld apparatus is configured to weigh less than about 1 kilogram (kg). In further aspects, the plasma sensor is positioned within an interior of the handheld 25 apparatus. In further aspects, the handheld laser system further includes an optical fiber coupling the handheld apparatus to the laser source. In some aspects, the handheld apparatus further includes a trigger coupled to at least one of the controller and a source of shield gas that controls activation of the shield gas. 30 In further aspects, the trigger is a first trigger and the handheld apparatus further comprises a second trigger coupled to at least one of the controller and the laser source feat controls activation of the laser source. In accordance with another aspect of the disclosure, a handheld laser system is provided that includes a laser source configured to generate laser radiation at a wavelength for performing a material processing operation on a workpiece material with a laser beam of the generated laser radiation, and a housing configured as a handheld apparatus having an 5 outlet for the laser beam, the handheld apparatus configured to be gas-cooled. fa further aspects, the handheld laser system includes an optical fiber coupling the handheld apparatus to the laser source. fa some aspects, the handheld apparatus is of one-piece construction. In some aspects, handheld apparatus is configured with a modular attachment system 10 for a nozzle. In some aspects, the handheld laser system further includes an air-cooling system coupled to the laser source for dissipating heat. In some aspects, the handheld laser system farther includes a laser module that houses the laser source, the air-cooling system, and the controller. 15 fa further aspects, the laser module is configured to be mounted to a movable cart., fa some aspects, the laser beam has a power of at least 1 kW. Still other aspects, embodiments, and advantages of these example aspects and embodiments, are discussed in detail below. Moreover, it is to be understood that both the foregoing information and the following detailed description are merely illustrative examples 20 of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Embodiments disclosed herein may he combined with other embodiments, and references fa “an embodiment,” fam example,” “some embodiments,” “some examples,” “an alternate embodiment,” “various embodiments,” “one embodiment,” “at least one embodiment,” “this 25 and other embodiments,” “certain embodiments,” or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described may be included in at least one embodiment The appearances of such terms herein are not necessarily all referring to the same embodiment 3b BRIEF DESCRIFriON OF DRAWINGS Various aspects of one or mure embodiments are discussed below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to provide an illustration and a further understanding of the various aspects and M&GUcal component that is illustrated in vanous figures is represented by a like nmnemL for DETAILED DESCRIPTION In accordance with certain embodiments, the handheld apparatus 120 has a weight of less than 5 pounds (2.27kg) (without fiber), and in some embodiments, the handheld apparatus 120 has a weight of less than 3 pounds (1.36kg). According to one embodiment, the handheld apparatus 120 has a weight of less than 1 kilogram (kg). In addition, the handheld apparatus 120 has length and width dimensions of less than 12 inches (30.48cm), e.g., see the side view perspective of the handheld apparatus 120 in FIG. 3F. In one example, the handheld apparatus 120 has a width dimension of less than 10 inches (25.4cm). The entire system 100, according to some embodiments, has a maximum weight of 53 kg (118 pounds). In accordance with at least one embodiment, the handheld apparatus 120 is of one-piece construction (also referred to as monolithic or integrated construction). The exterior of the handheld apparatus 120 is formed of a single integrated material, and not bolted or otherwise fastened together from separate sections. This type of construction allows for several advantages. For one thing, one-piece construction provides a more sealed internal environment when compared against devices configured with multi-part construction that are mechanically fastened together. This feature enhances protection of the internal components to the handheld apparatus 120, e.g., lenses and other optical components, optical fiber, gas lines, etc., and allows for higher output powers by the device. According to some embodiments, the handheld apparatus 120 is configured with a modular attachment system for a nozzle. This allows for the handheld apparatus 120 to function as a single “base” module, thus allowing substitution and flexibility in providing different attachment nozzles to the handheld apparatus 120 for various applications (e.g., cleaning, welding, drilling, cladding). This is implemented at least in part by the handheld apparatus 120 being configured to internally integrate several auxiliary and / or other components, such as shielding gas, a protective window(s), and safety features such as safety interlock conductors that are integrated within the interior of the handheld apparatus 120. The handheld apparatus 120 is also configured to have a clear line of sight (for the operator) to the processing area (i.e., where the material processing operation is occurring on the surface of the workpiece) of the workpiece 105. This is evidenced by the views shown in FIGS. 3C and 3D, where the angled portion 113 (see also FIG. 3F) of the handheld apparatus 120 is configured to not impede the line of sight along the dimension of the device that includes the nozzle 112. No other portion or attachment impedes this line of sight either. This allows the user to have a direct line of sight down to the nozzle tip and allows for better visibility for the user of the processing area during material processing operations. threshold value can also be set to take into account or otherwise accommodate applications where the laser is modulated (i.e., laser power varies, such as pulsed mode). For instance, the laser power can be modulated when the laser is functioning with wobble capability (described in more detail below). The controller 150 may be any computing device (or devices) that includes at least one processor, a memory, input / output components as will be readily appreciated by those of skill in the art, and is capable of receiving, transforming, and / or analyzing data from the plasma sensor 135. The controller 150 may include hardware and / or software capable of transforming and / or analyzing information from the plasma sensor 135 and other components of the device or system. The handheld laser system 100 also includes an air-cooling system 140 that is coupled to the laser source 115 for purposes of dissipating heat. As mentioned above, air-cooling the device greatly reduces the size of the system as compared to water or liquid refrigerant-based laser cooling systems. According to at least one embodiment, system 100 can also include a laser module 110 that houses the air-cooling system 140, laser source 115, and controller 150. As indicated in FIG. 1, the laser module 110 can be configured to be mounted to a movable cart 160. In one example, the movable cart 160 has the dimensions of a standard welding cart, e.g., 36 inches (91.44cm) or less in length and height, and 24 inches (60.96cm) or less in width, although it is to be appreciated that some welding carts may have dimensions that slightly differ or otherwise differ from those listed herein. According to one embodiment, the laser module 110 itself can be sized to be less than 26 inches (66.04cm) in length, less than 12.5 inches (31.75cm) in width, and less than or equal to 21 inches (53.34cm) in height. Referring now to FIGS. 3 A-3F, there are various views of one non-limiting example of a handheld apparatus 120 which has a size and shape for user portability for the purpose of performing laser material processing operations such as welding or cutting. In this example embodiment, the handheld laser device resembles a gun-shape. According to some embodiments, system 100 can also include a wire feeder module (not shown in figures) that can be configured as a separate module, or in some instances be integrated with the laser module 110. The controller 150 can also be configured to control this wire feeder module. In accordance with another aspect, the handheld apparatus 120 is configured to be gas-cooled. For instance, the handheld apparatus 120 may have one or more inlets for a gas such as a shielding gas (or air in certain applications) that is directed through one or more conduits within the interior of the handheld apparatus 120. This means that no cooling water

Claims

1. A handheld laser system, comprising:a laser source configured to generate laser radiation at a wavelength for performing a material processing operation on a workpiece material with a laser beam of the generated laser radiation;a housing configured as a handheld apparatus having an outlet for the laser beam, wherein the handheld apparatus is configured with at least one inlet for a shielding gas so as to be gas-cooled, the shielding gas exiting the handheld apparatus at the outlet to provide shield gas to the workpiece material; andan air-cooling system coupled to the laser source for dissipating heat from the lasersource.

2. The handheld laser system of claim 1, further comprising an optical fiber coupling the handheld apparatus to the laser source.

3. The handheld laser system of claim 1, wherein the handheld apparatus is configured with an attachment system for different nozzles.

4. The handheld laser system of claim 1, further comprising a laser module that houses the laser source, the air-cooling system, and the controller.

5. The handheld laser system of claim 4, wherein the laser module is configured to be mounted to a movable cart.

6. The handheld laser system of claim 1, wherein the laser beam has a power of at least 1 kW.

7. The handheld laser system of claim 1, wherein the handheld apparatus is configured to weigh less than 1 kilogram (kg).

8. The handheld laser system of claim 1, wherein the handheld apparatus comprises a trigger coupled to at least one of the controller and a source of the shielding gas that controls activation of the shielding gas.

59. The handheld laser system of claim 8, wherein the trigger is a first trigger and the handheld apparatus further comprises a second trigger coupled to at least one of the controller and the laser source that controls activation of the laser source.10 10. The handheld laser system of claim 9, wherein the first and second triggers areconfigured in a two-stage arrangement such that the second trigger will not activate the laser source unless the first trigger is activated.

11. The handheld laser system of claim 1, further comprising at least one movable mirror 15 positioned within the housing, the at least one movable mirror configured to wobble the laser beam.

12. The handheld laser system of claim 1, wherein the laser source is a fiber laser.

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