Galvanometer Calibration for Real-Time Laser and Measuring Light Alignment
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Solution Overview
Problem
In galvanometer laser welding systems, real-time alignment between the measuring light and the keyhole is challenging due to aberrations caused by field lenses of different wavelengths, making it difficult to detect penetration depth and locate the melt pool effectively.
Innovation Solution
A method involving a first and second galvanometer, where the first adjusts the processing laser and the second adjusts the measuring light, using region division and coordinate calibration to establish correspondences between reference coordinate systems and swinging angles, enabling real-time alignment through bilinear or trilinear interpolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a second galvanometer is used to scan and deflect the measuring light, then the measuring light can be guided to the laser processing surface, but the measuring light does not coincide with the processing laser after passing through the beam combiner, and real-time alignment becomes difficult
Solution Approach 1:
The patent performs preliminary calibration by dividing the processing area into multiple regions and establishing correspondence relationships between galvanometer swinging angles and regional coordinates in advance. This pre-established mapping enables real-time alignment without complex dynamic adjustments during actual processing.
Solution Approach 2:
The patent divides the laser processing surface into multiple selected regions and establishes correspondence relationships for each region separately. This segmentation approach simplifies the overall alignment problem by breaking it down into manageable regional mappings that can be calibrated and stored for quick reference during processing.
2Measurement precision
If the optical path is strictly adjusted to make measuring light coincide accurately with the processing laser, then initial alignment is improved, but aberrations produced by field lens for light of different wavelengths cause deviation on the welding surface
Solution Approach 1:
The patent applies different correspondence relationships for different regions of the processing surface, accounting for wavelength-specific aberrations in different areas. Each selected region has its own calibrated mapping between galvanometer angles and surface coordinates, allowing local compensation for optical aberrations.
3Measurement precision
If region division and coordinate calibration are performed, then real-time alignment between measuring light and keyhole is achieved, but the calibration process becomes more complex
Solution Approach 1:
The calibration process is simplified by dividing the processing area into multiple selected regions and establishing correspondence relationships for each region independently. This segmentation allows systematic calibration that can be performed methodically rather than attempting to calibrate the entire area as one complex unit.
Solution Approach 2:
The correspondence relationships between galvanometer swinging angles and regional coordinates are established in advance during calibration. This preliminary action creates lookup tables or mapping data that can be quickly referenced during real-time processing, eliminating the need for complex real-time calculations.
Data Source
AI summary
A method for adjusting swinging of a galvanometer is provided in implementations of the disclosure. The method includes the following operations. Guide a processing laser to a laser processing surface via a first galvanometer, and establish a first correspondence between a reference coordinate system of the laser processing surface and coordinate-ranges of swinging angles of the first galvanometer. Perform region division on the laser processing surface in the reference coordinate system to obtain P calibrating selected-regions of the laser processing surface. Determine coordinate of a swinging angle of the first galvanometer corresponding to one of target points in Q calibrating selected-regions in the P calibrating selected-regions according to the first correspondence, to obtain coordinates of Q swinging angles of the first galvanometer. Establish a second correspondence between the reference coordinate system of the laser processing surface and coordinate-ranges of swinging angles of a second galvanometer.