Coaxial Camera Laser Contour Tracking for Precise Processing
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Solution Overview
Problem
Existing laser processing systems face challenges in achieving precise laser processing along a contour path due to deviations between the expected and actual workpiece geometry, especially when manufacturing tolerances and workpiece shape variations occur, and require improved methods to determine the actual contour path accurately.
Innovation Solution
A method and system utilizing a coaxial camera arrangement to determine the actual contour path by analyzing one-dimensional measuring lines in the recorded image, allowing for precise control of the laser beam based on the actual geometry, reducing the need for complex image processing and enhancing speed and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predefined contour path is used for laser processing, then the processing speed is high, but the positioning accuracy deviates from the actual contour path due to manufacturing tolerances
Solution Approach 1:
The system performs preliminary optical detection of the workpiece contour before laser processing using a coaxial camera. The detected actual contour path is stored and used to guide the laser beam, ensuring the high-speed processing follows the precise actual geometry rather than an idealized predefined path.
Solution Approach 2:
The system uses optical feedback by continuously detecting the actual workpiece contour through the coaxial camera and adjusting the laser processing path in real-time. This closed-loop approach ensures the laser beam adapts to manufacturing tolerances and actual geometry deviations while maintaining high processing speed.
2Area of stationary object
If the camera field of view is increased to cover the entire workpiece, then the positioning coverage is improved, but the measurement precision decreases
Solution Approach 1:
The system segments the workpiece contour detection into multiple measuring lines that radiate from the center of the workpiece. Each measuring line independently detects contour points with high precision, and these segmented measurements are combined to reconstruct the complete contour path, achieving both full coverage and high precision.
Solution Approach 2:
The system transitions from two-dimensional area-based contour detection to one-dimensional line-based measurement. By using radial measuring lines that extend from the center to the contour, the system achieves precise 1D measurements along each line while collectively covering the entire 2D workpiece area, resolving the precision-coverage trade-off.
3Device complexity
If conventional image processing techniques are used to determine the contour path, then the system is simple, but the processing speed and precision are insufficient for complex contours
Solution Approach 1:
The system extracts only the essential contour information by using radial measuring lines that directly intersect the contour at specific points. Instead of processing the entire image to detect contours, the system extracts contour points along predefined radial lines, significantly reducing computational complexity while maintaining precision for complex geometries.
Solution Approach 2:
The system replaces conventional mechanical or computational image processing methods with an optical measurement approach. The coaxial camera combined with radial measuring line geometry provides direct optical determination of contour points, eliminating the need for complex image algorithms and achieving faster, more precise contour detection.
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
The method enables precise laser processing along the actual contour path, reducing manufacturing tolerances and increasing processing speed by up to 100 times compared to conventional techniques, while maintaining high recognition rates.
Implementation Method 1
an image of the workpiece is recorded with a camera
Implementation Method 2
a laser beam and a control device for controlling the scanning device to position the laser beam for laser processing
Data Source
AI summary
A method and a laser processing system are for laser processing a workpiece by a laser beam. The method includes: recording an image of the workpiece with a camera, the beam path of which is coaxially coupled into a beam path of the laser beam and runs together with the beam path of the laser beam via a scanning device; determining a respective contour point for each measuring line of a plurality of measuring lines which are laid through an expected contour path of the workpiece in the recorded image; determining an actual contour path of the workpiece based on the determined contour points; and controlling the scanning device for positioning the laser beam for laser processing based on the actual contour path.