Beam Tool Focus Calibration Using Bridge Test Cuts
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Solution Overview
Problem
Current methods for determining the focus position in laser-based machine tools are often manual or prone to subjective errors, making them inefficient and unreliable for precise machining processes.
Innovation Solution
A method involving a relative motion trajectory that creates a discoid area with bridge areas, where test cuts are performed at varying focus positions to evaluate cutting structures, allowing for automated determination of the reference focus position by assessing whether the workpiece has discs or openings, and assigning the focus position based on these evaluations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual or optical measurement methods are used to determine focus position, then the process can be performed with simple equipment, but the determination is prone to subjective errors and inefficiency
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical evaluation system. The beam-based machine tool performs test cuts at different focus positions, and an evaluation device automatically analyzes the cutting structures (discoid areas with bridges) to determine the reference focus position, eliminating subjective human error and improving both precision and efficiency.
Solution Approach 2:
The system performs self-diagnosis and self-calibration by automatically evaluating its own focus position through test cuts. The evaluation device analyzes the cutting structures produced by the beam and autonomously determines the optimal focus position without requiring external manual intervention, enabling the system to service itself.
2Measurement precision
If multiple test cuts are performed at different focus positions, then the measurement precision improves, but the setup time and complexity increase
Solution Approach 1:
The patent performs preliminary test cuts at multiple predetermined focus positions to establish a test field. By pre-defining the evaluation criteria (discoid area with bridges indicating correct focus), the system efficiently narrows down the optimal focus position without requiring exhaustive testing, thus balancing precision with time efficiency.
Solution Approach 2:
The evaluation device provides feedback by analyzing the cutting structures from test cuts and determining whether each focus position produces the desired discoid pattern with bridges. This feedback mechanism allows the system to iteratively refine the focus position determination, achieving high precision while minimizing the number of required test cuts through intelligent evaluation.
3Reliability
If automated evaluation of cutting structures is implemented, then reliability and reproducibility improve, but the device complexity increases
Solution Approach 1:
The patent introduces an intermediary evaluation device that acts as a mediator between the beam-based machining process and the focus position control system. This device automatically analyzes cutting structures and provides objective evaluation criteria, ensuring reliable and reproducible focus determination while isolating the complexity from the main machining system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables faster, more precise, and reproducible focus position determination, reducing error probability and simplifying the setup process for laser-based machining, applicable to various laser types and workpieces.
Implementation Method 1
beam-based, in particular laser-based, machine tools
Implementation Method 2
laser cutting
Implementation Method 3
bring the laser beam into contact with the workpiece at the point where the laser beam has the highest power density
Data Source
AI summary
Disclosed are methods of determining a reference focus position of a beam of a beam-based machine tool. The methods providing a relative motion trajectory defining a discoid area with respect to a surrounding area, the discoid area being connected to the surrounding area via at least one bridge area, and performing a sequence of test cuts on a workpiece, wherein at each test cut, a cutting structure is cut in the workpiece by guiding the beam along the relative motion trajectory and the cutting is performed along the at least one bridge area of the relative motion trajectory at differently set focus positions.