Coherence Imaging Beam Calibration for Precise Laser Registration
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Solution Overview
Problem
Current coherence imaging measurement systems face challenges in accurately and efficiently calibrating the alignment of measurement beams with processing beams in laser processing applications, requiring extensive expertise, time, and specific hardware configurations, which limits their precision and adaptability.
Innovation Solution
A system and method that includes a coherence imaging (CI) measurement system integrated with controllers to automatically calibrate the alignment of the CI measurement system with the processing beam, using calibration measurement outputs to modify future measurements, enabling static and dynamic calibrations, and improving registration accuracy and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used for coherence imaging measurement systems, then alignment accuracy can be achieved, but extensive expertise and time are required
Solution Approach 1:
The system performs preliminary calibration actions by establishing a reference frame using fiducial markers before actual measurement. The fiducial markers are positioned in advance and used to pre-align the measurement beam with the processing beam, eliminating the need for time-consuming iterative adjustments during operation.
Solution Approach 2:
Fiducial markers serve as intermediary objects that mediate between the processing beam and measurement beam alignment. These markers provide a common reference that both beams can be aligned to, simplifying the calibration process and reducing the expertise required while maintaining high alignment accuracy.
2Measurement precision
If traditional calibration methods are used for coherence imaging measurement systems, then alignment accuracy can be achieved, but extensive expertise is required
Solution Approach 1:
The system performs self-calibration by automatically detecting fiducial markers and computing alignment corrections without requiring operator intervention. The controller autonomously processes images of fiducial markers, calculates transformation parameters, and adjusts the measurement beam alignment, making the system easy to operate while maintaining high precision.
Solution Approach 2:
The patent replaces manual mechanical alignment procedures with automated optical and computational methods. Instead of requiring operators to physically adjust components based on expertise, the system uses optical detection of fiducial markers and computational algorithms to automatically achieve precise alignment.
3Measurement precision
If static calibration is performed, then registration accuracy is improved, but the system lacks adaptability to dynamic changes
Solution Approach 1:
The system transitions from static to dynamic calibration by continuously detecting fiducial markers during operation. The calibration parameters are not fixed but are dynamically updated based on real-time detection of fiducial marker positions, allowing the system to adapt to changes in the processing environment while maintaining high registration accuracy.
Solution Approach 2:
The system implements feedback mechanisms where the detection results of fiducial markers are fed back to continuously adjust alignment parameters. This closed-loop approach allows the system to maintain accurate registration despite dynamic changes in the processing setup, combining the precision of static calibration with the adaptability of dynamic adjustment.
4Measurement precision
If multiple fiducial markers are used for calibration, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The fiducial markers serve multiple functions: they provide alignment references, enable calibration, and can be used for ongoing verification. This multi-functionality allows the use of simple, universal marker designs that reduce overall system complexity while still achieving high alignment precision through their versatile application in the calibration process.
Data Source
AI summary
Systems and methods for static and dynamic calibration may be used to provide alignment of a measurement beam from a coherence imaging (CI) measurement system relative to a processing beam from a material processing system. In these systems and methods, a calibration measurement output may be obtained from the CI measurement system and/or from an auxiliary sensor. Future measurements performed by the CI measurement system may be modified based on, at least in part, the calibration measurement output.