Laser Machining Add-On Module for Automated Beam Centering
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Solution Overview
Problem
Current laser machining systems face challenges in efficient initial start-up, parameterization, and monitoring due to manual beam centering, lack of coordination among system components, and limited computing and storage capacity, requiring extensive expert knowledge and multiple devices for setup and control.
Innovation Solution
An add-on module intercoupling the control device and laser machining head, providing additional computing power, data storage, and interfaces for real-time data processing and analysis, enabling automated start-up, parameter adjustment, and predictive maintenance through sensors and AI, reducing the need for multiple devices and simplifying system upgrades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual beam centering is performed after each fiber insertion, then beam alignment can be achieved, but initial start-up time becomes excessively long
Solution Approach 1:
The system performs preliminary beam centering by capturing an image of the beam position before machining begins. The processing unit analyzes this image to determine the beam center position in advance, so that when machining starts, the beam is already centered and no time-consuming manual adjustment is needed during initial operation.
Solution Approach 2:
The system uses its own imaging device and processing unit to automatically perform beam centering without requiring external manual intervention. The control device autonomously captures the beam image, processes it to find the center position, and adjusts the beam alignment automatically, making the system self-sufficient for this critical setup task.
2Adaptability or versatility
If multiple separate devices are used for control, monitoring, and data processing, then system functionality is comprehensive, but device complexity increases
Solution Approach 1:
The patent combines multiple previously separate functions into a single integrated system. The control device now incorporates both the imaging device for beam centering and the processing unit for analyzing images and determining beam position. This merging eliminates the need for separate manual centering devices while maintaining comprehensive functionality.
Solution Approach 2:
The control device is designed with multi-functionality, serving both as the primary control unit for machining operations and as the image processing center for beam centering. The processing unit within the control device handles both machining control tasks and image analysis tasks, making the device universal and reducing the total number of components needed in the system.
3Manufacturing precision
If machining parameters are adjusted based on empirical values and expert knowledge, then parameter accuracy can be achieved, but parameterization becomes time-consuming and requires extensive expertise
Solution Approach 1:
The system implements feedback by capturing actual beam position data through imaging and using the processing unit to analyze this real information. Instead of relying on empirical estimates or expert guesses, the system receives feedback from the actual beam position and adjusts parameters based on measured data, achieving accurate parameterization automatically without requiring expert knowledge or time-consuming experimental adjustments.
4Ease of manufacture
If the control device has limited computing and storage capacity, then system cost is reduced, but ability to perform real-time data processing and monitoring is insufficient
Solution Approach 1:
The system segments the computing tasks by placing the imaging device and basic image processing functions in the control device, while more computationally intensive tasks can be distributed or performed on-demand. This segmentation allows the control device to maintain lower cost with basic processing capabilities while still achieving real-time functionality for critical operations like beam centering.
Data Source
AI summary
An add-on module for intercoupling or interposing between a control device, in particular a system control, and a laser machining head of a laser machining system is provided. The add-on module includes: a first interface, and is connectable with the laser machining head and/or with at least one sensor device of the laser machining system via the first interface so as to exchange data; a second interface, wherein the add-on module is connectable to the control device via the second interface so as to exchange data; and a processing unit configured to process data and output the processed data via at least one of the first, second, and third interfaces. Furthermore, a laser machining device includes such an add-on module is provided.