Handheld Laser Plasma Sensing for Reflection Shutoff
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Solution Overview
Problem
Handheld laser devices with high power levels pose safety hazards due to invisible laser energy reflection, and conventional cooling systems hinder maneuverability in small workspaces.
Innovation Solution
A handheld laser device equipped with a plasma sensor to detect plasma emission during processing, a controller to compare optical intensity values with a threshold, and an air-cooling system to reduce size and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power laser (at least 1 kW) is used for industrial cutting and welding, then productivity and manufacturing capability are improved, but safety hazards increase due to invisible laser energy reflection
Solution Approach 1:
The system uses a plasma sensor to detect plasma emission during laser processing and provides feedback to the controller. When plasma is detected (indicating proper absorption), the system continues operating. When no plasma is detected (indicating possible reflection), the controller shuts off the laser to prevent safety hazards. This feedback mechanism enables high power operation while mitigating reflection risks.
Solution Approach 2:
The system converts the harmful effect of invisible laser reflection into a detectable signal by using a plasma sensor. Plasma emission serves as a beneficial indicator that laser energy is being properly absorbed. The absence of plasma signals potential reflection, allowing the system to proactively prevent hazards while maintaining high productivity.
2Reliability
If large water-based or liquid refrigerant-based chillers are used to cool the laser, then laser operation reliability is improved, but device portability and ease of operation deteriorate due to large size
Solution Approach 1:
The invention extracts the cooling function from the traditional large water-based chiller system and implements it as a compact integrated cooling system within the handheld device. This extraction enables reliable laser operation while achieving the portability needed for small workspaces and irregular geometries.
Solution Approach 2:
The cooling system is nested within the handheld laser device structure, with the laser source, cooling mechanism, and control systems integrated into a single portable unit. This nesting approach maintains reliable cooling performance while achieving compact dimensions suitable for manual handling and use in confined spaces.
3Stability of the object's composition
If conventional large cooling systems are used, then laser power stability is improved, but device complexity and size increase
Solution Approach 1:
The invention merges the cooling system with the handheld laser device, integrating the laser source, cooling mechanism, plasma sensor, and controller into a unified compact system. This combination maintains laser power stability through effective cooling while reducing overall device complexity compared to separate conventional systems.
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
Prevents prolonged exposure to laser light by automatically shutting off the laser when reflection occurs, and allows for compact, portable operation in confined spaces.
Implementation Method 1
a plasma sensor configured to detect plasma emitted from the workpiece material during a material processing operation
Implementation Method 2
compare an optical intensity value obtained by the plasma sensor to a threshold value
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A handheld laser system. In certain examples the handheld laser system includes a laser source emitting laser light at a wavelength for performing a material processing operation on a workpiece material with a laser beam of the emitted laser light, a plasma sensor configured to detect plasma emitted from tire workpiece material daring a material processing operation, and a controller coupled to the plasma sensor and configured to: compare an optical intensity value obtained by the plasma sensor to a threshold value at a time when a predetermined time period has elapsed after the material processing operation has commenced, and produce a control command based on the comparison.