Laser Beam Analysis at Field-of-View Extremities
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Solution Overview
Problem
Existing laser processing systems, particularly those with high-speed motion capabilities, struggle to accurately analyze and adjust laser beam characteristics at field of view extremities, leading to inefficiencies and inconsistencies in processes like laser beam welding.
Innovation Solution
A system with pin-hole sensors mounted at the field of view extremities of high-speed laser motion systems, coupled with fiber optic cables and photodetectors, measures and adjusts laser beam characteristics, including spot size, shape, and irradiance, to ensure consistent processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If laser beam characteristics are analyzed only at the center location of the field of view, then the analysis system is simple and cost-effective, but the laser processing consistency at field of view extremities deteriorates
Solution Approach 1:
The field of view is segmented into multiple measurement zones: center location and multiple extremity locations. Pin-hole sensors are distributed at these segmented locations to independently measure laser beam characteristics at each zone, enabling comprehensive coverage without requiring a single complex centralized measurement system.
Solution Approach 2:
Pin-hole sensors serve as intermediary measurement devices between the laser beam and the detection system. These sensors are strategically positioned at field of view extremities to capture local beam characteristics, acting as mediators that transfer information about beam quality at critical locations back to the control system for compensation.
2Manufacturing precision
If multiple pin-hole sensors are mounted at field of view extremities to measure laser beam characteristics, then the manufacturing precision and processing consistency are improved, but the device complexity and cost increase
Solution Approach 1:
Instead of using a single high-precision measurement system that covers the entire field of view, the system implements local quality measurement by placing simple pin-hole sensors at specific critical locations (extremities) where beam characteristics most affect processing quality. Each sensor provides localized measurement data sufficient for its specific position.
Solution Approach 2:
The measurement approach uses simplified pin-hole sensor copies distributed at multiple locations rather than one complex measurement system. Each pin-hole sensor is a simple, inexpensive component that replicates the basic measurement function at different spatial positions, collectively providing comprehensive beam characterization.
3Ease of operation
If laser beam characteristics are not adjusted at field of view extremities, then the system operation is simple, but the processing quality and reliability at extremities deteriorate
Solution Approach 1:
The system implements feedback control by continuously monitoring laser beam characteristics at field of view extremities using pin-hole sensors and automatically adjusting processing parameters based on measured deviations. The control system receives real-time data from extremity sensors and applies compensatory adjustments to maintain consistent processing quality throughout the field of view.
Solution Approach 2:
The system performs preliminary characterization of laser beam characteristics at field of view extremities during system setup and calibration phases. This preliminary measurement data is used to pre-establish compensation profiles and lookup tables that enable automatic real-time adjustments during actual processing operations, eliminating the need for complex real-time calculations.
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 precise analysis and adjustment of laser beam characteristics at both center and extremities of the field of view, enhancing the consistency and efficiency of high-speed laser processing systems.
Implementation Method 1
the photodetector converts the laser light delivered to the photodetector into electrical voltage output signals based on intensity of the laser light received through each pin-hole sensor
Data Source
AI summary
A system for analyzing laser beam characteristics at field of view extremities in high-speed laser motion systems, wherein the high-speed laser motion systems comprise a laser that generates a non-stationary laser beam and a build platform positioned at a predetermined location relative to the non-stationary laser beam, comprising a known or pre-defined field of view of the laser, wherein the laser beam characteristics are known or determined at a center location of the field of view; and a plurality of pin-hole sensors mounted at the field of view extremities, wherein each pin-hole sensor measures the laser beam characteristics at the field of view extremities, and wherein differences between the laser beam characteristics at the center location and the laser beam characteristics at the field of view extremities are captured and accounted for in the high-speed laser motion system during processing.