Modular handheld laser material processing system

Abstract

The present disclosure provides a torch type detection system comprising a torch detector (410) configured to detect a type of torch (400) coupled to a control unit (492) via an umbilical (450), and a controller (480) configured to store predefined operational parameters associated with different torch types and to apply the predefined operational parameters upon detection of a corresponding torch type. The torch detector (410) comprises an electronic sensor configured to detect a unique identifier associated with the torch (400), wherein the unique identifier comprises an RFID tag, barcode, or electrical contacts. The predefined operational parameters include laser power range, wobble functionality, or gas flow control. The controller (480) is configured to lock or unlock laser system features based on the detected torch type.

Description

Attorney Docket No.: 5117.0026W01MODULAR HANDHELD LASER MATERIAL PROCESSING SYSTEMCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims the benefit of U.S. Provisional Application No. 63 / 707035, titled MODULAR HANDHELD LASER MATERIAL PROCESSING SYSTEM, filed October 14, 2024, the contents of which are expressly incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates to handheld laser systems, and more particularly to a modular laser system with a torch for material processing having interchangeable components and programmable features for improved functionality and user experience.BACKGROUND

[0003] Handheld laser material processing systems have gained popularity due to their portability and precision. These systems typically consist of a laser generation unit, handheld tool, and connecting cables. While laser technology has advanced with higher power and lower costs, traditional systems face limitations including inflexibility of stationary setups, ergonomic challenges, and adaptability issues. Conventional handheld tools require multiple discrete connections for laser fiber, process gas, and electrical systems, creating cumbersome setup procedures. Additionally, optics systems are susceptible to contamination from processing debris, and existing protective window replacement procedures are tedious and risk exposing internal components to contaminants.SUMMARY

[0004] In some examples, the disclosure describes a torch type detection system that includes a torch detector configured to detect a type of torch coupled to a control unit via an umbilical, and a controller configured to store predefined operational parameters associated with different torch types and to apply the predefined operational parameters upon detection of a corresponding torch type by the torch detector.

[0005] In some examples, the disclosure describes a nozzle type detection system for a torch that includes a nozzle detector configured to detect a type of nozzle coupled to the torch, and processing circuitry configured to automatically adjust operational parameters of a laser system based on the detected nozzle type.

[0006] In some examples, the disclosure describes a user replaceable trigger module for a torch that includes a first trigger and a second trigger, each removably coupled to a shell of the torch to enable toolless removal, a first contact operably coupled to the first trigger andAttorney Docket No.: 5117.0026W01 configured to receive a signal indicative of an actuation of the first trigger, and a second contact operably coupled to the second trigger and configured to receive a signal indicative of an actuation of the second trigger, wherein the first contact and second contact are compatible with collaborative robot applications.

[0007] In some examples, the disclosure describes a universal integrated termination head receptacle for modular handheld laser tools that includes a laser fiber receptacle configured to receive a laser fiber from a unified termination head, electrical receptacles configured to receive electrical couplings from the unified termination head, a process gas receptacle configured to receive process gas ports from the unified termination head, and a physical mechanical receptacle configured to receive a mechanical coupling from the unified termination head, wherein the universal integrated termination head receptacle enables a modular family of torches to be used with a same laser power and control unit.

[0008] Features and advantages of the present disclosure include, but are not limited to, (1) the torch type detection system enables automatic configuration of operational parameters based on the specific tool type, reducing setup time and improving operational efficiency; (2) the nozzle type detection system provides automatic adjustment of laser parameters based on nozzle configuration, enhancing welding quality and preventing damage from incorrect settings; (3) the user replaceable trigger module allows for field replacement without tools and provides compatibility with collaborative robot applications, increasing system flexibility and reducing downtime; (4) the universal integrated termination head receptacle enables modular use of different torches with the same control unit, providing cost savings and operational versatility;(5) the cartridge-based protective window replacement mechanism prevents exposure of internal optics to contamination during window changes, extending equipment life and maintaining optical performance; (6) the integrated umbilical with unified termination head reduces connection complexity by combining laser fiber, electrical, and gas connections into a single coupling; (7) the capacitance-based substrate proximity detection system enables uninterrupted welding over gaps and nonconductive materials, improving weld continuity and quality; (8) the two-axis laser beam wobbling mechanism allows projection of any shape onto the weld surface, providing enhanced control over weld geometry; (9) the voice control system enables hands-free parameter adjustment during welding operations, improving workflow efficiency and safety; and (10) the material configuration database with learning capability automatically optimizes welding parameters based on substrate material and user history, reducing setup time and improving weld consistency.Attorney Docket No.: 5117.0026W01BRIEF DESCRIPTION OF FIGURES

[0009] FIG. 1 is a conceptual diagram illustrating an example laser system with a torch connected via an umbilical cord.

[0010] FIG. 2 is a conceptual diagram illustrating an example perspective view of a torch performing a welding operation.

[0011] FIG. 3 is a conceptual diagram illustrating an example perspective view of internal components and sensor arrangement of the torch.

[0012] FIG. 4 is a conceptual diagram illustrating an example perspective view of a torch with a protective window cartridge.

[0013] FIG. 5 is a conceptual diagram illustrating an example cross-sectional view of the torch showing internal optical components.

[0014] FIG. 6 is a conceptual diagram illustrating an example cross-sectional and exploded view of a protective window receiving region.

[0015] FIG. 7 is a conceptual diagram illustrating an example side elevational view of a torch.

[0016] FIG. 8 is a conceptual diagram illustrating an example side elevational view of a torch in an exploded configuration.

[0017] FIG. 9 is a conceptual diagram illustrating an example side view of an umbilical with a unified termination head.

[0018] FIG. 10 is a conceptual diagram illustrating an example cross-sectional view of the unified termination head.

[0019] FIG. 11 is a conceptual diagram illustrating an example perspective view of a unified termination head configured to couple with a torch.

[0020] FIG. 12 is a conceptual diagram illustrating an example perspective view of a torch with receptacles for the unified termination head.

[0021] FIG. 13 is a conceptual diagram illustrating an example block diagram of a modular handheld laser system.DETAILED DESCRIPTION

[0022] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0023] Referring to FIG. 1, a laser system 100 may include a laser power control unit 104, a modular handheld laser tool (referred to as torch 106), and an umbilical cord 108 connectingAttorney Docket No.: 5117.0026W01 control unit 104 and torch 106. Umbilical cord 108 may connect to torch 106 at a removable connection 110. Torch 106 may include a handgrip portion 112 having first trigger 113A and second trigger 113B and joining to a body portion 114. The body portion 114 may include a laser discharge end 115, and a nozzle 116 may be removably attached at laser discharge end 115.

[0024] Control unit 104 may include various components for generating and controlling laser radiation. In some cases, control unit 104 includes a laser energy generation source that produces a laser beam 120. Control unit 104 may also include a controller 121 for managing system operations. A process gas control system 123 may be provided within control unit 104 to control process gas delivery to torch 106. Additionally, a coolant system 125 may be incorporated to manage thermal conditions during operation.

[0025] Laser system 100 may be configured to perform material processing operations on a workpiece 124. Workpiece 124 may be electrically connected to control unit 104 through a conductive wire 126. This electrical connection may complete a closed circuit when nozzle 116 contacts workpiece 124, ensuring that laser beam 120 is properly directed toward workpiece 124. During operation, laser beam 120 emitted from laser discharge end 115 may generate plasma 122 at the point of contact with workpiece 124.

[0026] The modular design of laser system 100 may provide flexibility for various material processing applications. Removable connection 110 between umbilical cord 108 and handgrip portion 112 may allow for easy attachment and detachment of different torches. Umbilical cord 108 may contain multiple conduits including optical fibers for laser transmission, electrical wiring for power and control signals, and gas lines for process gas delivery, all integrated within a single flexible assembly.

[0027] Referring to FIG. 2, torch 106 may be configured to perform welding operations on workpiece 124. During operation, torch 106 may emit laser beam 120 from laser discharge end 115, generating plasma 122 at the point of contact with workpiece 124. Plasma 122 may create a weld 128 on workpiece 124 through the controlled application of laser energy and optional material deposition, e.g., via a wire feeder or the like. Torch 106 may include a torch body 130 that houses various internal components for directing and controlling laser beam 120, including first trigger 113A and second trigger 113B for controlling operation of torch 106.

[0028] The welding process may generate various outputs that can be monitored and analyzed for quality assessment. An acoustic output 131 may be produced during the welding operation as plasma 122 interacts with workpiece 124. Additionally, a spectral radiation output 133 may be emitted from plasma 122 during the welding process. These outputs may provide valuable information about the welding operation and weld quality.Attorney Docket No.: 5117.0026W01

[0029] Torch 106 may include an optics system 136 positioned within torch body 130.Optics system 136 may contain various optical components for directing and shaping laser beam 120. A protective window 134 may be positioned as a forward-most component of optics system 136, serving to protect internal optical elements from contamination and debris generated during welding operations. Optics system 136 may include a wobble unit 138 configured to manipulate a path of laser beam 120. Wobble unit 138 may contain an oscillating mirror 139 and galvanometer 137 that can move to create various beam patterns on workpiece 124. This beam manipulation capability may enhance welding performance by allowing for different weld geometries and improved heat distribution.

[0030] Referring to FIG. 3, torch 106 may incorporate multiple sensors for monitoring welding operations and system status. An acoustic sensor 142 may be positioned to detect acoustic output 131 generated during welding. Acoustic sensor 142 may enable acoustic spectral analysis of the welding process, allowing the system to correlate acoustic patterns with specific weld characteristics. This acoustic analysis may provide feedback for automatically adjusting operational parameters such as laser power, process gas flow rate, or wobble characteristics to optimize weld quality.

[0031] A spectral radiation sensor 146 may be configured to detect spectral radiation output 133 emitted from plasma 122. Spectral radiation sensor 146 may enable spectral analysis of plasma 122 associated with the welding operation. This spectral analysis may reflect weld characteristics associated with weld quality and may provide data for automatically adjusting operational parameters including laser power, wire feed rate, or torch travel rate.

[0032] Torch 106 may also include a temperature sensor 143 for monitoring thermal conditions within torch body 130. A protective window sensor 150 may be provided to assess the condition of protective window 134. In some cases, protective window sensor 150 may include an LED paired with a light sensor to quantify transparency and contamination levels on protective window 134. Protective window sensor 150 may detect laser light that is deflected from contamination present on protective window 134, providing an indication of when protective window 134 may need replacement.

[0033] Torch 106 may include a cartridge 140 for storing replacement protective windows. An insertion mechanism 141 may be operably coupled to cartridge 140 to facilitate replacement of protective window 134 without requiring disassembly of torch 106. This configuration may allow for efficient maintenance of optics system 136 while minimizing exposure of internal components to environmental contaminants.

[0034] Referring to FIG. 4, a torch 200 may be configured with a modular design for enhanced functionality and user operation. Torch 200 may include a distal tip 202 extendingAttorney Docket No.: 5117.0026W01 from a shaft 204. Shaft 204 may be removably engaged by a coupling 206 to a head unit 210. This modular configuration may allow for interchangeable components and simplified maintenance operations.

[0035] Head unit 210 may include a pistol grip 212 that provides an ergonomic grip for user operation. Pistol grip 212 may support a first trigger 214 and a second trigger 216, which may be configured to control various operational parameters of torch 200. In some cases, first trigger 214 and second trigger 216 may be programmable to enable user customization of trigger functions. A mode selection switch 218 may be positioned on head unit 210 to allow users to toggle between different operational modes without requiring access to a separate control unit.

[0036] Torch 200 may include a protective window cartridge 220 extending from head unit 210 and operably coupled to a lever 222 for manual actuation as indicated by arrow 223, where a shell 224 with shell portion 225 may enclose various components including an exchange module 226 with window ejector 228 and loader 230 configured to facilitate replacement of protective windows as indicated by arrow 227 while minimizing exposure of internal optical components to environmental contaminants. Protective window cartridge 220 may hold multiple pre-cleaned protective windows in a stacked arrangement, with a replacement window 268 positioned within protective window cartridge 220 for insertion into laser path 260 when protective window 266 requires replacement. This configuration may enable rapid replacement of protective windows without exposing internal optical components to environmental contaminants, and exchange module 226 may include a retainer mechanism that secures protective windows in position along laser path 260, where the retainer may be biased toward a protective window seat to maintain proper positioning of protective window 266.

[0037] Torch 200 may be configured to connect to an umbilical 250 that provides laser energy, electrical power, control signals, and process gas to torch 200. Umbilical 250 may enable communication between torch 200 and a laser power control unit. A nozzle 203 may be positioned at the distal end of torch 200 to direct laser energy toward a workpiece during material processing operations.

[0038] Referring to FIG. 5, torch 200 may include internal optical components arranged along laser path 260. Laser path 260 may traverse through multiple optical elements to direct and condition laser energy for material processing operations. A collimating lens 262 may be positioned along laser path 260 to collimate incoming laser radiation. Laser path 260 may continue through a focus lens 264 that focuses the laser beam toward the workpiece. A protective window 266 may be positioned at the distal end of laser path 260 to protect internal optical components from debris and contamination generated during welding operations.Attorney Docket No.: 5117.0026W01

[0039] Torch 200 may include a galvanometer 240 configured to manipulate the laser beam along laser path 260. Galvanometer 240 may include a mirror 242 that can be positioned to redirect laser energy. An electric motor 244 may be operably coupled to the mirror 242 to provide controlled movement of the mirror 242. Electrical contacts 246 may be provided to supply power and control signals to the electric motor 244. This configuration may enable precise control of laser beam positioning and wobble patterns during material processing operations. Although described as including only one galvanometer, in other examples, torch 200 may include two galvanometers configured to enable dual axis wobble.

[0040] Torch 200 may include multiple sensors positioned to monitor various aspects of system operation. A protective window photodiode 261 may be positioned to detect laser light scattered by contamination on protective window 266. A thermosensor 263 may be positioned to monitor temperature conditions within torch 200. A plasma sensor 265 may be configured to detect plasma characteristics during welding operations. In some examples, a spectrometer may be positioned near plasma sensor 265 to enable laser-induced breakdown spectroscopy (LIBS) or similar techniques. In some examples, torch 200 may include additional sensors, such as, for example, one or more inertial mass unit (IMU) sensors, accelerometers, gyroscopes, image sensors (e.g., visible-spectrum, RGB, monochrome, or infrared cameras), acoustic sensors (e.g., microphones or speakers), capacitance sensors, volatile organic compound sensors, or other sensors configured to monitor a state of torch 200 or a laser material processing process. These sensors may provide feedback for system control and maintenance scheduling.

[0041] Torch 200 may include a display 219 positioned on head unit 210 to provide visual feedback to users. Display 219 may show operational parameters, system status, or maintenance alerts. In some cases, display 219 may include a touchscreen interface for user input and system configuration. Display is positioned to enable a user to visualize both display 219 and distal tip 202 simultaneously to provide visual feedback to users regarding system status, operational parameters, or maintenance alerts.

[0042] Referring to FIG. 6, the torch may be viewed from a front perspective showing distal tip 202, shell 224, pistol grip 212, and the arrangement of external components accessible to users during operation. For example, first trigger 214 and second trigger 216 may be supported by pistol grip 212 in positions that enable intuitive finger placement for trigger actuation, coupling to a mount of a cobot, or both. First trigger 214 and second trigger 216 may be configured as user-replaceable components that can be removed and installed without requiring tools or disassembly of torch 200. Mode selection switch 218 may be positioned on shell 224 in a location that provides easy access for users to change operational modes during welding operations.Attorney Docket No.: 5117.0026W01

[0043] Referring to FIG. 7, torch 200 may be viewed from a rear perspective that shows pistol grip 212, umbilical 250, lever 222, shell 224, mode selection switch 218, and display 219. Mode selection switch 218 may be positioned on shell 224 to allow users to toggle between different operational parameters or welding modes while maintaining a grasp of pistol grip 212. In some cases, mode selection switch 218 may enable switching between tack welding and continuous welding operations without requiring users to access a separate control unit. In some examples, mode selection switch 218 may be modular such that it may be mounted to either a left surface of right surface of shell 224 to accommodate either lefthanded or highhanded operation.

[0044] Referring to FIG. 8, a torch 300 is configured in an exploded arrangement to illustrate the modular construction and user-replaceable components. Torch 300 may be the same as or substantially similar to torch 106 and torch 200, except for the differences described herein. For example, torch 300 includes a distal tip 302 extending from a shaft 304, a coupling 306 that removably engages shaft 304 to a head unit 310, a nozzle 303 positioned at the distal end, a chassis 311 that defines a portion of a pistol grip 312, a first trigger 314 and a second trigger 316 supported by the pistol grip 312, a first contact 315 operably coupled to first trigger 314, a second contact 317 operably coupled to the second trigger 316, a mode selection switch 318 positioned on head unit 310, a cartridge 320 extending from head unit 310, a hinge 321 operably coupling cartridge 320 to a lever 322, a shell 325 that encloses various components, a window exchange unit 326 couplable to head unit 310, an ejector 328 configured to translate through an ejector aperture 329, a loader 330 positioned to interact with ejector 328, a galvanometer 340 having a mirror 342, an electric motor 344, and electrical contacts 346, an umbilical 350 with a unified termination head 351, a laser fiber 352, electrical contacts 354, and process gas ports 356 within unified termination head 351, a focus lens 364 positioned along the optical path, and a protective window 366 positioned at the distal end of the optical path. Additionally, torch 300 includes a sensor suite including, for example, a thermosensor 363 for monitoring temperature conditions within the tool, a plasma sensor 365 configured to detect plasma characteristics during material processing operations, and auxiliary sensors 367 and 369 which may include, for example, an IMU, accelerometer, gyroscope, or any other suitable type of sensor configured to monitor operational parameters or system status.

[0045] Torch 300 may include a distal tip 302 extending from a shaft 304 that may be removably engaged by a coupling 306 to a head unit 310. A nozzle 303 may be formed by distal tip 302, shaft 304, and coupling 306 to direct laser energy toward a workpiece during material processing operations. A focus lens 364 may be positioned along the optical path to focus laser energy toward the workpiece. A protective window 366 may be positioned at the distal end ofAttorney Docket No.: 5117.0026W01 the optical path to protect internal optical components from debris and contamination generated during material processing operations. Protective window 366 may be replaceable using the cartridge 320 and associated replacement mechanisms without requiring disassembly of torch 300.

[0046] Torch 300 may include a process gas delivery system wherein process gas from process gas ports 356 of unified termination head 351 of umbilical 350 may be directed through a cavity defined by at least chassis 311 toward an gas manifold 370, through a gas profiler 371 that is configured to provide a selected gas flow profile (e.g., substantially laminar flow with a Reynolds number less than 4000 or less than 2300) through shaft 304 to distal tip 302, providing shielding gas during material processing operations and reducing debris and contamination intrusion into the optical components of torch 300.

[0047] Chassis 311 may provide structural support for various internal and external components of torch 300. First trigger 314 and second trigger 316 may each be removably coupled to shell 325 to enable toolless removal. For example, first trigger 314 and second trigger 316 may be retained within trigger apertures defined by shell 325 via a friction fit, which may allow users to remove and install first trigger 314 and second trigger 316 without requiring tools or disassembly of torch 300. A first contact 315 may be operably coupled to first trigger 314 and configured to receive a signal indicative of an actuation of first trigger 314. A second contact 317 may be operably coupled to the second trigger 316 and configured to receive a signal indicative of an actuation of the second trigger 316.

[0048] In some cases, first contact 315, second contact 317, or both may include an analog optical switch including a light source and an aperture controlled by depression of the respective trigger, where the measured intensity of the light varies based on the analog depression of the trigger to provide a digital light intensity signal as an output of the respective contact.

[0049] First contact 315 and second contact 317 may remain communicatively coupled to torch 300 when first trigger 314 and second trigger 316 are removed. In some cases, the communication of signals indicative of actuation between the triggers and contacts may not require a wired connection.

[0050] Any combination of first trigger 314, second trigger 316, first contact 315, and second contact 317 may be compatible with collaborative robot (“cobot”) applications. For example, a mount of a cobot may be configured to physically depress first trigger 314, second trigger 316, or both when torch 300 is coupled to a mount of a cobot. Additionally, or alternatively, first trigger 314 and second trigger 316 may be replaceable with sensor-based triggers for cobot applications. In some cases, the cobot applications may include a cobot mountAttorney Docket No.: 5117.0026W01 having protrusions configured to be received within the trigger apertures and communicatively coupled to first contact 315 and second contact 317.

[0051] In some examples, first trigger 314 and second trigger 316 may be configured as multi-stage triggers. Each stage of the multi-stage triggers may be independently programmable to select from a list of preprogrammed functions. The list of preprogrammed functions may include at least one of wire feed rate control, wobble frequency control, wobble amplitude control, or variable power level control. In some cases, at least one of first trigger 314 and second trigger 316 may include an analog trigger configured to provide variable control signals based on actuation level.

[0052] Mode selection switch 318 may be positioned on the head unit 310 to allow users to select different operational parameters or modes. The mode selection switch 318 may enable switching between various welding operations without requiring access to a separate control unit.

[0053] Torch 300 may be configured to couple to umbilical 350 that provides laser energy, electrical power, control signals, and process gas. Umbilical 350 may include a unified termination head 351 that enables simultaneous connection of multiple services, including a laser fiber 352 for transmitting laser radiation, electrical contacts 354 for power and control signals, and process gas ports 356 for delivering process gas to torch 300.

[0054] Referring to FIGS. 9 and 10, umbilical 350 may be configured with unified termination head 351 at a distal end to provide a consolidated connection interface for torch 300. Unified termination head 351 may integrate multiple connection types within a single termination assembly, enabling simultaneous connection of laser energy transmission, electrical power and control signals, and process gas delivery. This integrated design may eliminate the need for separate connections and may reduce the complexity of coupling operations between umbilical 350 and torch 300.

[0055] Unified termination head 351 includes laser fiber 352 centrally positioned within unified termination head 351 to provide optical coupling for laser energy transmission from a laser power control unit (e.g., control unit 104) to torch 300. Electrical contacts 354 may be arranged around laser fiber 352 in a radial configuration within unified termination head 351 to provide electrical power and control signal transmission and enable simultaneous electrical connection when unified termination head 351 is coupled to torch 300. Process gas ports 356 may be positioned within unified termination head 351 to provide gas flow paths that align with corresponding gas receptacles in torch 300 and deliver process gas for material processing operations. A mechanical coupling 358 may be provided within unified termination head 351 to secure the connection between umbilical 350 and torch 300 while maintaining proper alignment of laser fiber 352, electrical contacts 354, and process gas ports 356.Attorney Docket No.: 5117.0026W01

[0056] Unified termination head 351 may include alignment and guide structure that facilitates reliable connection with torch 300. The alignment structure may ensure proper positioning of laser fiber 352, electrical contacts 354, and process gas ports 356 relative to corresponding receptacles in torch 300. This alignment capability may enable users to make connections easily and reliably without requiring precise manual alignment of individual connection components.

[0057] Unified termination head 351 may enable sequential coupling of connection components during attachment to torch 300. Laser fiber 352 may be configured to couple first with a corresponding laser fiber receptacle in torch 300. Optionally, process gas ports 356 may couple with corresponding process gas receptacles after laser fiber 352 connection is established. The electrical contacts 354 may complete the connection sequence by engaging with corresponding electrical receptacles in torch 300.

[0058] Mechanical coupling 358 may provide rotational orientation between unified termination head 351 and torch 300 during the connection process. Mechanical coupling 358 may also provide locking capability to secure unified termination head 351 to torch 300 after all connection components are properly engaged. In some examples, mechanical receptacle 378 may include a ball-bearing expansion lock mechanism. This locking mechanism may prevent accidental disconnection during material processing operations while maintaining reliable connection of all services provided through the umbilical 350.

[0059] The unitary connector design of unified termination head 351 may enable modular compatibility with different torch configurations. Unified termination head 351 may be configured to mate with various torch types while providing consistent connection interfaces for laser fiber 352, electrical contacts 354, and process gas ports 356. This modular capability may allow users to interchange different torches with the same umbilical 350 and laser power control unit configuration.

[0060] Referring to FIGS. 11-12, torch 300 may be configured with a universal integrated termination head receptacle 353 that enables modular compatibility with unified termination head 351. Universal integrated termination head receptacle 353 may include multiple specialized receptacles configured to receive corresponding components from unified termination head 351. This receptacle configuration may enable a modular family of torches to be used with the same laser power and control unit.

[0061] Universal integrated termination head receptacle 353 may include a laser fiber receptacle 372 configured to receive laser fiber 352 from unified termination head 351. Laser fiber receptacle 372 may be configured to contain and direct laser radiation along an optical path defined by torch 300. In some cases, laser fiber receptacle 372 may be configured to sequentiallyAttorney Docket No.: 5117.0026W01 couple with laser fiber 352 before other connection components are engaged. This sequential coupling arrangement may ensure proper optical alignment before establishing electrical and optional gas connections.

[0062] Universal integrated termination head receptacle 353 may include electrical receptacles 374 configured to receive the electrical contacts 354 from unified termination head 351. Electrical receptacles 374 may include a plurality of sockets configured to receive a corresponding plurality of pins from unified termination head 351. Electrical receptacles 374 may be configured to provide electrical power and controller communication to torch 300. In some cases, electrical receptacles 374 may be positioned in an annular arrangement around laser fiber receptacle 372 to enable simultaneous electrical connection when unified termination head 351 is coupled to torch 300.

[0063] Universal integrated termination head receptacle 353 may include a process gas receptacle 376 configured to receive the process gas ports 356 from unified termination head 351. Process gas receptacle 376 may be configured to receive a selected shielding gas including at least one of an inert gas, nitrogen, or argon. In some examples, process gas receptacle 376 may be defined by a portion of chassis 311. Process gas receptacle 376 may provide gas flow paths that enable delivery of process gas to torch 300 during material processing operations.

[0064] Universal integrated termination head receptacle 353 may include a mechanical receptacle 378 configured to receive mechanical coupling 358 of unified termination head 351. Mechanical receptacle 378 may be configured to rotationally orient torch 300 with unified termination head 351 during the connection process. Mechanical receptacle 378 may also be configured to lock torch 300 to unified termination head 351 after all connection components are properly engaged. In some cases, mechanical receptacle 378 may be configured to constrain torch 300 entirely when coupled with unified termination head 351.

[0065] The sequential coupling process enabled by universal integrated termination head receptacle 353 may begin with laser fiber receptacle 372 receiving laser fiber 352 to establish optical coupling. Process gas receptacle 376 may then receive process gas ports 356 to establish gas flow connections. Electrical receptacles 374 may complete the connection sequence by receiving the electrical contacts 354 to establish power and control signal transmission. Mechanical receptacle 378 may provide final securement and locking of the connection assembly.

[0066] The modular design of universal integrated termination head receptacle 353 may enable compatibility with various torch configurations. The modular family of torches may include at least one of a single axis wobble tool, a dual axis wobble tool, a cleaning tool, a cutting tool, or a non- wobble tool. Each tool type may incorporate the same universal integratedAttorney Docket No.: 5117.0026W01 termination head receptacle 353 configuration to enable interchangeability with unified termination head 351.

[0067] In some cases, universal integrated termination head receptacle 353 may be configured to recognize various torch configurations and automatically adjust operational parameters based on the detected torch configuration. This recognition capability may be achieved through multiple detection methods, including electronic identification systems such as RFID tags embedded within each torch type that transmit unique identification codes to an RFID reader positioned within universal integrated termination head receptacle 353 or control unit. Alternatively, the recognition may be accomplished through optical identification systems such as barcode readers configured to scan barcode labels affixed to each torch, wherein different barcode patterns correspond to specific tool types and operational parameter sets. In some implementations, the recognition may utilize electrical contact-based identification systems wherein each torch type includes a unique arrangement of electrical contacts or resistive elements that create distinctive electrical signatures when coupled to universal integrated termination head receptacle 353, enabling the system to identify the tool type based on measured electrical characteristics such as resistance values, voltage patterns, or current flow characteristics. Additionally, the recognition may be achieved through mechanical identification systems wherein each torch type includes unique mechanical features such as keying arrangements, pin configurations, or physical dimensions that are detected by corresponding mechanical sensors or switches within universal integrated termination head receptacle 353. In some cases, the recognition may employ magnetic identification systems utilizing magnetic elements embedded within each torch that are detected by magnetic sensors, or optical identification systems using infrared or visible light sensors to detect unique optical patterns or reflective elements associated with each tool type. This recognition capability may enable the laser system to automatically configure appropriate settings for different tool types, including laser power ranges, wobble functionality, or gas flow control parameters. The automatic adjustment capability may enhance system adaptability and may reduce the need for manual parameter configuration when switching between different torch types.

[0068] Referring to FIG. 13, a modular handheld laser system 490 may be configured with a comprehensive control architecture that enables advanced detection capabilities and automated parameter adjustment. Modular handheld laser system 490 may include a torch 400 connected to a control unit 492 and a remote device 494 via an umbilical 450. This integrated configuration may provide centralized control and monitoring capabilities for various torch types and operational modes.Attorney Docket No.: 5117.0026W01

[0069] Torch 400 may include a controller 480 configured to manage system operations and coordinate communication between various system components. Controller 480 may include a processor 482 configured to execute control algorithms and process sensor data. A memory 484 may be operably coupled to processor 482 to store operational parameters, user preferences, and system configuration data. An operations module 486 may be configured to control operational parameters of modular handheld laser system 490 in response to user inputs or sensor feedback. Communications circuitry 488 may be provided to enable data transmission and reception between controller 480 and other system components.

[0070] Controller 480 may be connected to a sensor suite 496, an input suite 498, and an output suite 499 to provide comprehensive monitoring and control capabilities. Sensor suite 496 may include multiple sensors configured to monitor various aspects of system operation and material processing performance. Input suite 498 may include various user interface components that enable operator control and system configuration. Output suite 499 may include feedback devices configured to provide visual, audible, or tactile feedback to a user during operation.

[0071] Modular handheld laser system 490 may include a torch type detection system configured to automatically identify and configure operational parameters based on the type of torch connected to the system. A torch detector 410 may be configured to detect a type of torch coupled to control unit 492 via umbilical 450. Torch detector 410 may include an electronic sensor configured to detect a unique identifier associated with torch 400. In some cases, the unique identifier may include one of an RFID tag, a barcode, or a set of electrical contacts that provides identification information to torch detector 410.

[0072] Controller 480 may be configured to store predefined operational parameters associated with different torch types and to apply the predefined operational parameters upon detection of a corresponding torch type by torch detector 410. The predefined operational parameters may include at least one of laser power range, wobble functionality, or gas flow control. Controller 480 may be further configured to automatically adjust the predefined operational parameters based on the detected torch type. In some cases, controller 480 may be configured to lock or unlock certain features of the laser system based on the detected torch type. The certain features may include at least one of laser power settings, wobble amplitude control, or process gas flow rate control.

[0073] Torch detector 410 may be positioned within control unit 492 and configured to detect the torch type upon connection of torch 400 to umbilical 450. The different torch types may include at least one of a single axis wobble tool, a dual axis wobble tool, a cleaning tool, a cutting tool, or a non-wobble tool. Controller 480 may be further configured to store userAttorney Docket No.: 5117.0026W01 preferences associated with each detected torch type and to apply the user preferences along with the predefined operational parameters.

[0074] Modular handheld laser system 490 may include a nozzle type detection system configured to automatically adjust operational parameters based on the type of nozzle coupled to the torch. A nozzle detector 403 may be configured to detect a type of nozzle coupled to the torch. The nozzle detector 403 may include an electronic sensor configured to detect a unique identifier associated with the nozzle. The unique identifier may comprise one of an RFID tag, a barcode, or a set of electrical contacts that enables automatic nozzle identification.

[0075] Processor 482 may be configured as processing circuitry to automatically adjust operational parameters of the laser system based on the detected nozzle type. The operational parameters may include at least one of laser power, wobble amplitude, or process gas flow rate. Processor 482 may be further configured to store predefined parameter sets associated with different nozzle types and to apply a corresponding predefined parameter set upon detection of a nozzle type. The predefined parameter sets may include optimized settings for at least one of welding operations, cleaning operations, or cutting operations.

[0076] Processor 482 may be further configured to limit or unlock certain functions of the laser system based on the detected nozzle type. The certain functions may include at least one of maximum laser power output, wobble pattern selection, or wire feed rate control. Processor 482 may be further configured to provide visual or audible feedback to a user upon detection of the nozzle type. The visual feedback may comprise displaying the detected nozzle type and corresponding operational parameters on a display 419 integrated with torch 400.

[0077] Sensor suite 496 may include multiple sensors configured to monitor various aspects of material processing operations and system performance. A photodiode 461 may be positioned to detect laser light scattered by contamination on protective windows and / or to monitor plasma characteristics during welding operations. A thermosensor 463 may be configured to monitor temperature conditions within the torch or at specific optical components. A plasma sensor 465, which may include a spectrometer, may be configured to detect plasma intensity and spectral characteristics during material processing operations. An acoustic sensor 467 may be configured to detect sound patterns generated during material processing operations. The acoustic sensor 467 may enable acoustic spectral analysis that can be correlated with weld quality characteristics. A back reflection sensor 469 may be configured to monitor laser radiation reflected back toward the torch during material processing operations. The back reflection sensor 469 may enable control of weld depth by detecting when a keyhole has opened during welding operations, as back reflection of laser radiation may drop appreciably once the keyhole forms. A capacitance sensor 471 may be configured to provide capacitance-based substrate proximityAttorney Docket No.: 5117.0026W01 detection without requiring physical contact, allowing for uninterrupted material processing operations over gaps, corners, and nonconductive materials.

[0078] Input suite 498 may include various user interface components that enable operator control and system configuration. A first trigger 414 and a second trigger 416 may be configured to provide user control over laser activation and operational parameters. A mode switch 418 may enable users to select different operational modes or parameter sets. The display 419 may provide visual feedback regarding system status, operational parameters, and detected component types.

[0079] Output suite 499 may include various feedback devices configured to enhance user interaction and system operation. Output suite 499 may include a voice control system configured with an actuator, microphone, and speaker for dictating instructions to controller 480 and associated applications. The voice control system may enable users to adjust operational parameters through voice commands during material processing operations.

[0080] Modular handheld laser system 490 may include a material configuration database stored in the memory 484. The material configuration database may store welding parameters optimized for different materials and may be configured to learn from user input history. The database may include configurations for various material types, with each configuration including optimized settings for laser power, wobble parameters, process gas flow rates, and other operational parameters.

[0081] The system may include a learning mechanism that updates material configurations in real-time based on user adjustments during welding operations. When users modify operational parameters during material processing, the learning mechanism may automatically update the corresponding material configuration in the database. This adaptive capability may enable the system to continuously improve parameter optimization based on user preferences and operational experience.

[0082] Umbilical 450 may provide communication pathways between torch 400, control unit 492, and remote device 494. Umbilical 450 may enable transmission of control signals, sensor data, and operational parameters between system components. The remote device 494 may provide additional processing capability, data storage, or user interface functionality for modular handheld laser system 490.

[0083] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

Attorney Docket No.: 5117.0026W01CLAIMS1. A torch type detection system, comprising: a torch detector configured to detect a type of torch coupled to a control unit via an umbilical; and a controller configured to store predefined operational parameters associated with different torch types and to apply the predefined operational parameters upon detection of a corresponding torch type by the torch detector.

2. The torch type detection system of claim 1, wherein the torch detector comprises an electronic sensor configured to detect a unique identifier associated with the torch.

3. The torch type detection system of claim 2, wherein the unique identifier comprises one of an RFID tag, a barcode, or a set of electrical contacts.

4. The torch type detection system of claim 1, wherein the predefined operational parameters include at least one of laser power range, wobble functionality, or gas flow control.

5. The torch type detection system of claim 4, wherein the controller is further configured to automatically adjust the predefined operational parameters based on the type of torch.

6. The torch type detection system of claim 1, wherein the controller is further configured to lock or unlock certain features of a laser system based on the type of torch.

7. The torch type detection system of claim 6, wherein the certain features include at least one of laser power settings, wobble amplitude control, or process gas flow rate control.

8. The torch type detection system of claim 1, wherein the torch detector is positioned within the control unit and configured to detect the type of torch upon connection of the torch to the umbilical.

9. The torch type detection system of claim 1, wherein the different torch types include at least one of a single axis wobble tool, a dual axis wobble tool, a cleaning tool, a cutting tool, or a non-wobble tool.Attorney Docket No.: 5117.0026W0110. The torch type detection system of claims 1 or 8, wherein the controller is further configured to store user preferences associated with each detected torch type and to apply the user preferences along with the predefined operational parameters.

11. A nozzle type detection system for a torch, comprising: a nozzle detector configured to detect a type of nozzle coupled to the torch; and processing circuitry configured to automatically adjust operational parameters of a laser system based on the type of detected nozzle.

12. The nozzle type detection system of claim 11, wherein the nozzle detector comprises an electronic sensor configured to detect a unique identifier associated with the nozzle.

13. The nozzle type detection system of claim 12, wherein the unique identifier comprises one of an RFID tag, a barcode, or a set of electrical contacts.

14. The nozzle type detection system of claim 11, wherein the operational parameters include at least one of laser power, wobble amplitude, or process gas flow rate.

15. The nozzle type detection system of claim 14, wherein the processing circuitry is further configured to store predefined parameter sets associated with different nozzle types and to apply a corresponding predefined parameter set upon detection of a nozzle type.

16. The nozzle type detection system of claim 15, wherein the predefined parameter sets include optimized settings for at least one of welding operations, cleaning operations, or cutting operations.

17. The nozzle type detection system of claim 11, wherein the processing circuitry is further configured to limit or unlock certain functions of the laser system based on the type of nozzle.

18. The nozzle type detection system of claim 17, wherein the certain functions include at least one of maximum laser power output, wobble pattern selection, or wire feed rate control.

19. The nozzle type detection system of claims 11 or 17, wherein the processing circuitry is further configured to provide visual feedback or audible feedback to a user upon detection of the type of nozzle.Attorney Docket No.: 5117.0026W0120. The nozzle type detection system of claim 19, wherein the visual feedback comprises displaying the type of nozzle and corresponding operational parameters on a display integrated with the torch.

21. A user replaceable trigger module for a torch, comprising: a first trigger and a second trigger, each removably coupled to a shell of the torch to enable toolless removal; a first contact operably coupled to the first trigger and configured to receive a signal indicative of an actuation of the first trigger; and a second contact operably coupled to the second trigger and configured to receive a signal indicative of an actuation of the second trigger, wherein the first contact and second contact are compatible with collaborative robot applications.

22. The user replaceable trigger module of claim 21, wherein the first trigger and second trigger are each configured as multi-stage triggers.

23. The user replaceable trigger module of claim 22, wherein each stage of the multi-stage triggers is independently programmable to select from a list of preprogrammed functions.

24. The user replaceable trigger module of claim 23, wherein the list of preprogrammed functions includes at least one of wire feed rate control, wobble frequency control, wobble amplitude control, or variable power level control.

25. The user replaceable trigger module of claim 21, wherein the first trigger and second trigger are retained within trigger apertures defined by the shell via a friction fit only.

26. The user replaceable trigger module of claim 25, wherein the first contact and second contact remain communicatively coupled to the torch when the first trigger and second trigger are removed.

27. The user replaceable trigger module of claim 21, wherein the first trigger and second trigger are replaceable with sensor-based triggers for collaborative robot applications.Attorney Docket No.: 5117.0026W0128. The user replaceable trigger module of claim 27, wherein the collaborative robot applications include a cobot mount configured to interface with at least one of the first trigger, the second trigger, the first contact, and the second contact.

29. The user replaceable trigger module of claim 21, wherein at least one of the first trigger and second trigger comprises an analog trigger configured to provide variable control signals based on actuation level.

30. The user replaceable trigger module of claims 21, wherein communication of signals indicative of actuation between the first trigger and second trigger does not require a wired connection.

31. A universal integrated termination head receptacle for modular handheld laser tools, comprising: a laser fiber receptacle configured to receive a laser fiber from a unified termination head; electrical receptacles configured to receive electrical couplings from the unified termination head; a process gas receptacle configured to receive process gas ports from the unified termination head; and a physical mechanical receptacle configured to receive a mechanical coupling from the unified termination head, wherein universal integrated termination head receptacle enables a modular family of torches to be used with the unified termination head.

32. The universal integrated termination head receptacle of claim 31, wherein the laser fiber receptacle is configured to contain and direct laser radiation along an optical path defined by a torch.

33. The universal integrated termination head receptacle of claim 32, wherein the laser fiber receptacle is configured to sequentially couple with a laser fiber before the electrical receptacles and process gas receptacle are coupled.

34. The universal integrated termination head receptacle of claim 31, wherein the electrical receptacles comprise a plurality of sockets configured to receive a corresponding plurality of pins from the unified termination head.Attorney Docket No.: 5117.0026W0135. The universal integrated termination head receptacle of claim 34, wherein the electrical receptacles are configured to provide electrical power and controller communication to a torch.

36. The universal integrated termination head receptacle of claim 31, wherein the process gas receptacle is configured to receive a selected shielding gas comprising at least one of an inert gas, nitrogen, or argon.

37. The universal integrated termination head receptacle of claim 31, wherein the physical mechanical receptacle is configured to rotationally orient a torch with the unified termination head and lock the torch to the unified termination head.

38. The universal integrated termination head receptacle of claim 37, wherein the physical mechanical receptacle is configured to constrain a torch entirely when coupled with the unified termination head.

39. The universal integrated termination head receptacle of claim 31, wherein the modular family of torches includes at least one of a single axis wobble tool, a dual axis wobble tool, a cleaning tool, a cutting tool, or a non-wobble tool.

40. The universal integrated termination head receptacle of claims 31 or 39, wherein the universal integrated termination head receptacle comprises a unique identifier associated with a torch, wherein the unique identifier is readable by a torch type detection system.

Images