Laser Optical Axis Confirmation Using Image-Based Plane Alignment
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Solution Overview
Problem
Laser processing apparatuses with complex optical systems face difficulties in adjusting the optical axis of laser beams, leading to potential defects in workpiece processing, such as oblique processing or uneven groove processing, due to the subjective and indefinite nature of current methods for confirming the tilt of the optical axis.
Innovation Solution
A method involving a laser processing apparatus with a chuck table, a laser beam applying unit, and a moving assembly that uses image capturing units to quantify the alignment of optical axes by capturing images of the laser beam before and after reflection by specific optical devices, determining if they exist in the same plane, and adjusting their positions or tilts accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional eye measurement method is used to confirm laser beam tilt, then the operation is simple, but the measurement precision is indefinite and subjective
Solution Approach 1:
The patent replaces the human eye measurement system with an automated image processing system using a camera and computer. The system captures images of the laser beam and workpiece, then uses image processing algorithms to automatically calculate the laser beam's incident angle and position. This substitution transforms the subjective visual assessment into an objective, quantifiable measurement system, resolving the contradiction between operational simplicity and measurement precision.
Solution Approach 2:
The patent introduces an intermediary measurement system consisting of a camera, image processing unit, and calculation unit. This intermediary captures the laser beam's actual position and orientation, processes the images to extract geometric information, and calculates precise alignment parameters. This intermediary layer enables accurate measurement without requiring direct human visual judgment, thus improving measurement precision while maintaining ease of operation through automation.
2Adaptability or versatility
If complex optical system is used for laser processing, then the processing capability is improved, but the device complexity increases making optical axis adjustment difficult
Solution Approach 1:
The patent implements a self-service adjustment system where the measurement and calculation unit automatically determines the optical axis alignment status and provides quantitative feedback. The system captures images of the laser beam passing through multiple optical components, processes these images to calculate the actual optical path, and compares it with the ideal optical path. This self-service approach eliminates the need for complex manual adjustment procedures, resolving the contradiction between processing capability and adjustment difficulty.
Solution Approach 2:
The patent establishes a feedback loop where the image processing and calculation unit continuously monitors the optical axis alignment and provides quantitative feedback on the actual versus ideal positions. This feedback mechanism enables operators to make precise adjustments based on objective data rather than trial-and-error, significantly simplifying the adjustment process for complex optical systems while maintaining high processing capability.
3Loss of time
If manual optical axis adjustment is performed without quantitative measurement, then the adjustment process is quick, but the manufacturing precision of laser processing deteriorates
Solution Approach 1:
The patent performs preliminary measurement and calculation of the optical axis alignment before actual laser processing begins. The system captures images of the laser beam and optical components, calculates the actual optical path and incident angles in advance, and identifies any deviations from the ideal alignment. This preliminary action allows operators to make necessary adjustments before processing, ensuring high manufacturing precision without significant time loss, as the measurement and calculation are automated and rapid.
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 method allows for a quantitative assessment of the optical axes' alignment, ensuring accurate and parallel orientation of laser beams, thereby preventing processing defects and improving the precision of laser processing operations.
Implementation Method 1
an image capturing unit for capturing an image of the laser beam
Implementation Method 2
a first optical device having a line of intersection with an XZ plane perpendicular to an XY plane lying parallel to the X-axis directions and the Y-axis directions, for reflecting the laser beam into a direction parallel to the XZ plane
Implementation Method 3
a second optical device for reflecting the laser beam reflected by the first optical device to change a traveling direction of the laser beam within the XZ plane
Implementation Method 4
a third optical device for reflecting the laser beam whose traveling direction has been changed by the second optical device into a direction parallel to the XZ plane
Data Source
AI summary
A method of confirming an optical axis of a laser processing apparatus includes placing an image capturing unit so as to be movable in X-axis directions, removing a second mirror and capturing an image of a laser beam with the image capturing unit for receiving the laser beam reflected by a first mirror, installing the second mirror and capturing an image of the laser beam with the image capturing unit for receiving the laser beam reflected by a third mirror, and determining whether an optical axis of the laser beam reflected by the first mirror and an optical axis of the laser beam reflected by the third mirror exist in one XZ plane or not on the basis of the captured images and a reference line in the captured images.