Coaxial Laser Machining Calibration for Scanner Position Accuracy
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Solution Overview
Problem
Conventional laser machining systems face challenges in accurately calibrating scanner devices and coaxial observation devices due to non-linear relationships between scanner settings and focus positions, geometric and optical distortions, and chromatic aberration, which are difficult to address without external instruments.
Innovation Solution
A method for calibrating a laser machining system that uses a coaxial observation device to determine the relationship between a world coordinate system and scanner settings, allowing for calibration of both the scanner device and the observation device without external measurement instruments, using a calibration plate with a calibration pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If geometric and optical distortions are simulated using ray tracing software, then the mapping between world coordinate system and scanner coordinate system can be determined, but positioning error increases to approximately 500 μm or more
Solution Approach 1:
The laser machining system calibrates itself using its own observation device and laser beam without requiring external measurement instruments. The system uses the observation device to capture images of laser markings on the workpiece and automatically determines scanner calibration data through coordinate transformation, making the system self-calibrating and eliminating dependency on external equipment while achieving high precision.
Solution Approach 2:
The system uses the observation device to capture real-time images of laser markings and feeds this visual information back to the control device. The control device then calculates the actual positions of laser markings and compares them with expected positions, using this feedback to determine and adjust scanner calibration data, thereby continuously improving positioning accuracy.
2Measurement precision
If the scanner device and observation device are calibrated separately due to chromatic aberration, then each device can be optimized for its specific wavelength, but the calibration process becomes more complex and time-consuming
Solution Approach 1:
The system merges the calibration processes of the scanner device and observation device into a unified procedure. By using the observation device to capture images of laser markings and performing coordinate transformations that account for chromatic aberration, the system simultaneously calibrates both devices without requiring separate external instruments for each, thereby simplifying the overall calibration process while maintaining high accuracy.
3Manufacturing precision
If external measurement instruments are used for calibration, then high positioning accuracy can be achieved, but the calibration process requires additional equipment and increases costs
Solution Approach 1:
The laser machining system uses its own built-in observation device and laser beam to perform self-calibration without requiring any external measurement instruments. The observation device captures images of laser markings on the workpiece, and the control device processes these images to determine scanner calibration data, making the system completely self-sufficient and eliminating the need for additional expensive external equipment.
Solution Approach 2:
The observation device serves multiple functions: it acts as both the calibration tool for the scanner device and the process monitoring device during actual laser machining operations. This multi-functionality eliminates the need for separate external measurement instruments, reducing system complexity and costs while maintaining high calibration accuracy.
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 method enables accurate synchronization of the observation and scanner coordinate systems, reducing positioning errors and improving precision in laser machining systems, while eliminating the need for external instruments, thus increasing efficiency and reducing costs.
Implementation Method 1
a scanner device for deflecting a laser beam to a plurality of positions on a surface
Implementation Method 2
an observation device, the observation beam path of which runs coaxially to the laser beam path via the scanner device
Data Source
AI summary
A method for calibrating a laser machining system includes a scanner device for deflecting a laser beam to a plurality of positions on a surface and includes an observation device, an observation beam path of which runs coaxially to the laser beam path over the scanner device. The method includes calibrating the scanner device and calibrating the observation device. A laser machining system for machining a workpiece by means of a laser beam with a control configured to carry out said method is also provided.