Dynamic Focus Calibration in 3-Axis Laser Scanning
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Solution Overview
Problem
Existing three-axis galvanometric scanning systems face challenges in accurately calibrating the dynamic focus module, leading to poor mark quality due to misalignment of the focus point, which affects precision in laser processing.
Innovation Solution
A method is introduced to assess focus calibration errors by commanding the system to draw specific patterns on a work piece, utilizing an imaging system to analyze laser marking artifacts, and correlating these artifacts to predefined focus offsets, enabling precise calibration of the dynamic focus module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional validation methods are used to check laser aim, then calibration accuracy can be assessed, but the process requires large physical space and time-consuming manual inspection
Solution Approach 1:
The patent transitions from physical space inspection to digital image space analysis. By capturing laser marking artifacts through an imaging system and analyzing them in the digital domain, the method eliminates the need for large physical inspection areas while maintaining measurement precision. The digital processing of marking artifacts allows accurate focus calibration assessment without requiring extensive physical space.
Solution Approach 2:
The patent creates a digital copy of the laser marking artifacts through imaging system capture. Instead of directly inspecting physical marks on the workpiece, the method uses digital images of these artifacts for analysis. This copying approach enables precise measurement without occupying large physical inspection space and allows automated processing instead of manual inspection.
2Manufacturing precision
If dynamic focus module is miscalibrated, then laser processing precision deteriorates, but traditional calibration methods are time-consuming and require manual intervention
Solution Approach 1:
The system performs self-calibration by automatically analyzing its own laser marking artifacts. The imaging system captures the artifacts, and the processor automatically extracts focus calibration information from these artifacts without requiring external manual intervention. This self-service approach dramatically reduces calibration time while maintaining high manufacturing precision.
Solution Approach 2:
The patent implements a feedback mechanism where laser marking artifacts are captured and analyzed to determine focus calibration status. The system uses the information from these artifacts to assess and adjust the dynamic focus module calibration, creating a closed-loop feedback system that quickly achieves precise calibration without time-consuming manual procedures.
3Manufacturing precision
If focus point is misaligned with work piece surface, then mark quality deteriorates, but detecting this misalignment requires complex measurement procedures
Solution Approach 1:
The patent introduces laser marking artifacts as an intermediary indicator for detecting focus misalignment. Instead of directly measuring the complex three-dimensional focus position, the system analyzes two-dimensional marking artifacts that automatically encode focus calibration information. This intermediary approach simplifies the detection process while maintaining accuracy in assessing mark quality.
Solution Approach 2:
The patent utilizes visual characteristics of laser marking artifacts, including their appearance, contrast, and pattern features, as indicators of focus calibration status. By analyzing these visual properties captured in images, the system can detect focus misalignment without requiring complex measurement equipment or procedures, thereby maintaining high mark quality assessment capability.
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 allows for efficient and accurate validation of focus calibration within a reduced physical area, improving mark quality and processing precision without requiring large-scale manual inspection.
Implementation Method 1
an X-Y scan head module including two mirrors each rotatable by a galvanometric motor is located along a laser beam path between a laser device and a work piece
Implementation Method 2
In the dynamic focus module, one or more lenses move relative to the laser device to move a point of focus of the laser beam along a third axis (the Z direction)
Implementation Method 3
utilizing an imaging system to analyze laser marking artifacts
Data Source
AI summary
Some embodiments may include a method assessing whether a dynamic focus module in a three axis galvanometric scanning system (three-axis GSS) is associated with a focus calibration error. The method may include identifying a reference layer associated with a surface of the work piece and positive and negative offset distances each a difference distance above or below the reference layer, respectively, and selecting a target pattern based on the offset distances, wherein the pattern includes an individual line for each offset distance. The method may include commanding the three-axis GSS to draw the target pattern on the work piece, and then assessing whether the dynamic focus module is associated with the focus calibration error by correlating laser marking artifacts on the work piece to ones of the individual lines of the selected pattern. Other embodiments may be disclosed and/or claimed.