Laser Beam Detection for CNC Optical Misalignment Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Optical systems in CNC machines are prone to misalignment during shipping, assembly, and user intervention, leading to potential misdirection of laser beams, which can cause material destruction and safety hazards.

Innovation Solution

Implementing fixed optical components and a beam detection system to prevent misalignment, along with a control unit that alters the execution rate of operations to ensure smooth deceleration and re-acceleration, and a housing that dissipates and absorbs electromagnetic energy to enhance safety and reduce escape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If optical components are made adjustable to allow user configuration, then ease of operation is improved, but reliability deteriorates due to potential misalignment during user intervention

Engineering Contradiction:

Improveuser configuration capabilityVSAvoidoptical alignment stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The optical components are pre-aligned and fixed at the factory with precise alignment procedures performed before shipping. This preliminary action ensures that the optical system maintains correct alignment without requiring user adjustment, thereby preserving reliability while still allowing operational flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Alignment marks and reference features are incorporated into the optical component design, creating a reproducible alignment template. These marks serve as guides for re-alignment if disassembly occurs, ensuring that the original alignment can be replicated without requiring expert intervention.

Inventive Principle:

Principle #26Copying

2Object-affected harmful factors

If beam detection systems are added to detect interference, then safety is improved, but device complexity increases

Engineering Contradiction:

Improvelaser beam misdirectionVSAvoidsystem component count

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

A beam detection system using optical sensors and detectors is introduced as an intermediary between the laser source and the work area. This mediator monitors the laser beam path for anomalies such as misdirection or interference, triggering safety responses without requiring complex mechanical intervention systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The beam detection system continuously monitors the laser path and provides real-time feedback to the control system. When interference or misalignment is detected, the system automatically adjusts or shuts down the laser to prevent harmful effects, creating a closed-loop safety mechanism that manages complexity through automated control.

Inventive Principle:

Principle #23Feedback

3Reliability

If fixed optical components are used to prevent misalignment, then reliability is improved, but ease of operation deteriorates due to reduced adjustability

Engineering Contradiction:

Improveoptical alignment stabilityVSAvoidsystem setup flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

All optical components are pre-aligned and secured in fixed positions during manufacturing with high-precision alignment procedures. This preliminary action eliminates the need for user adjustment while maintaining operational flexibility through software control of the laser parameters and head movement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Mechanical adjustment mechanisms are replaced with fixed optical mounts and alignment features. Instead of allowing mechanical movement of optical components, the system uses software-controlled laser beam steering and fixed optical paths to achieve the desired flexibility without compromising alignment stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Prevents misalignment and unintended beam diversion, ensuring safe and controlled machining operations while minimizing material damage and operator exposure to electromagnetic energy.

Implementation Method 1

measuring a power of the beam of electromagnetic energy at a location between a source of the electromagnetic energy and the destination

Methodology Applied

Scientific EffectElectromagnetic radiation detection: Photoelectric Effect

Implementation Method 2

a housing that dissipates and absorbs electromagnetic energy to enhance safety and reduce escape

Methodology Applied

Scientific EffectElectromagnetic energy absorption: Absorption (EM radiation)

Data Source

PatentUS12420355B2Laser fabrication with beam detection

Publication Date: 2025.09.23 MAKEBLOCK HONGKONG HOLDING LTD

AI summary

A computer-numerically-controlled (CNC) machine is configured to (i) measure a power of a beam of electromagnetic energy at a location between a source of the electromagnetic energy and a destination in the CNC machine, the beam of electromagnetic energy traveling from the source to the destination being susceptible to one or more interferences, and the one or more interferences being capable of altering the power of the beam of electromagnetic energy by at least diverting, away from an intended path for the beam of electromagnetic energy, at least a portion of the beam of electromagnetic energy, (ii) detect, based at least on the measured power of the beam of electromagnetic energy being less than a threshold value, an interference of the beam of electromagnetic energy, and (iii) in response to detecting the interference of the beam of electromagnetic energy, perform one or more actions.