Laser Beam Alignment Calibration for Precise Probe-Based Machining
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Solution Overview
Problem
Laser beam machines with touch probes or electric capacity sensors suffer from measurement errors due to the relative position between the sensor and the laser beam machining head not being accurately measured, leading to reduced machining accuracy.
Innovation Solution
A laser beam machine and method that utilize a calibration unit with a measurement reference, an optical sensor, and a probe to form a machined mark on a workpiece, allowing for precise measurement of the deviation between the laser beam's machining point and the workpiece's position, enabling accurate alignment and machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch probe or electric capacity sensor is attached to the laser beam machining head, then the dimensions and shape of the workpiece can be measured, but measurement errors occur due to the unknown relative position between the sensor and the laser beam machining head
Solution Approach 1:
The patent replaces the mechanical attachment method with an optical measurement system. A camera is mounted on the laser beam machining head to optically measure the workpiece, eliminating the need for mechanical touch probes or electric capacity sensors. This allows the relative position between the measurement device and laser beam to be precisely determined through optical coordinate transformation, thereby resolving the measurement error issue while maintaining machining accuracy.
2Manufacturing precision
If the relative position between the sensor and laser beam machining head is not measured, then the setup is simple, but the measurement results include errors that lower machining accuracy
Solution Approach 1:
The patent eliminates complex mechanical positioning and sensor attachment procedures by using a camera-based optical measurement system. The camera is directly mounted on the laser beam machining head, and coordinate transformation algorithms are used to calculate the relative position between the camera and laser beam. This approach simplifies the overall system while achieving high measurement and machining accuracy.
Solution Approach 2:
The patent introduces a camera as an intermediary measurement device between the laser beam machining head and the workpiece. The camera captures images of the workpiece, and through coordinate transformation calculations, the system determines the precise relative position between the camera and laser beam. This intermediary approach enables accurate measurement without requiring direct mechanical contact or complex sensor positioning.
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 high-accuracy machining by calculating and correcting the relative positions of the workpiece and the laser beam, improving the precision of the machining process.
Implementation Method 1
measuring, by an optical sensor mounted to the optical head, the position of the machined mark on the to-be-processed part
Implementation Method 2
forming a machined mark with the laser beam on the to-be-processed part of the calibration unit
Implementation Method 3
irradiating the laser beam to the workpiece
Data Source
AI summary
This laser processing machine, which moves a work piece, which is mounted on a table, and an optical head, which shines a laser light, relative to each other, and processes the work piece by irradiating the work piece with the laser light, is provided with: a calibration camera that is fixed to the optical head; a probe that is fixed to the optical head; and a calibration unit that has measurement reference points (Pc1, Pc2, Pc3, Pp1, Pp2, Pp3) for measuring the position of the calibration camera and the probe, and a processing portion that forms a processing mark (L1, L2) due to the laser light.