Hybrid Laser Processing Head for Wavelength-Based Abnormality Detection
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Solution Overview
Problem
Conventional laser processing systems using hybrid laser beams with different wavelengths face challenges in determining the processing state of the workpiece and the internal state of the laser processing head due to the difficulty in separating reflected return light from the workpiece and vignetting light in optical components, especially when multiple optical components are involved.
Innovation Solution
A laser processing head with a housing containing separate optical paths for two laser beams of different wavelengths, equipped with photodetectors that receive light in specific wavelength bands, allowing for the determination of the processing state by analyzing the output signals of these photodetectors to distinguish between return light from the workpiece and vignetting light from optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hybrid laser processing system uses two types of laser beams with different wavelengths, then the processing capability and versatility are improved, but the complexity of determining the internal state of the laser processing head and separating return light from vignetting light increases
Solution Approach 1:
The detection function is segmented by wavelength: a first photodetector detects light in a first wavelength band (including the first laser beam wavelength), and a second photodetector detects light in a second wavelength band (including the second laser beam wavelength). This segmentation allows independent analysis of each wavelength component, simplifying the separation of return light from vignetting light in the hybrid laser system
Solution Approach 2:
Photodetectors serve as intermediary devices that convert optical signals (return light and vignetting light) into electrical signals for analysis. The photodetectors are positioned to receive light through the optical fiber, acting as intermediaries between the laser processing head internal state and the control system that determines abnormalities
2Manufacturing precision
If multiple optical components are disposed in the optical path, then the laser beam control and processing precision are improved, but the difficulty of detecting and measuring the internal state of the laser processing head increases
Solution Approach 1:
The system implements feedback by detecting light (including return light from the workpiece and vignetting light from optical components) with photodetectors, converting it to electrical signals, and analyzing these signals to determine the internal state of the laser processing head. This feedback mechanism enables real-time monitoring of optical component conditions without interfering with the processing precision provided by multiple optical components
Solution Approach 2:
The photodetectors perform multiple functions: they detect both return light from the workpiece and vignetting light from optical components through the same optical fiber pathway. This multi-functionality allows simultaneous monitoring of both processing state and internal component state without adding separate detection pathways that would complicate the optical system
3Reliability
If spatter adheres to optical components, then the laser beam is scattered and processing quality deteriorates, but the ability to detect this condition through return light analysis is reduced due to mixed signals
Solution Approach 1:
The detection is segmented by wavelength bands using photodetectors tuned to specific wavelength ranges. Since spatter contamination affects different wavelengths differently and the photodetectors analyze each wavelength band separately, the system can identify contamination patterns more precisely by comparing signals across wavelength bands, maintaining measurement precision even when spatter is present
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
Enables accurate determination of the processing state and internal state of the laser processing head, thereby preventing processing defects and maintaining quality by detecting abnormalities in the system.
Implementation Method 1
a first photodetector provided around the optical path of the first laser beam entering through the first light entrance port, and a second photodetector provided around the optical path of the second laser beam entering through the second light entrance port
Data Source
AI summary
Laser processing head 10 includes housing 11 and a plurality of optical components. Housing 11 is provided with partition wall 11a, first and second light entrance ports 12a, 12b through which first and second laser beams A, B respectively enter, and light irradiation port 13. Laser processing head 10 includes first and second photodetectors 91b, 92a provided around first and second light entrance ports 12a, 12b, respectively. First photodetector 91b is disposed opposite to second photodetector 92a across partition wall 11a. First photodetector 91b receives light in the second wavelength band including the wavelength of second laser beam B, and second photodetector 92a receives light in the first wavelength band including the wavelength of first laser beam A.