Laser Beam Position Detection Using a Calibrated Hole Sensor
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Solution Overview
Problem
Existing methods for detecting the position of high-power laser beams in additive manufacturing are inadequate, as they are not effective for immaterial beams and primarily designed for low-power lasers, making it difficult to ensure precise alignment and traceability in industrial applications.
Innovation Solution
A detection device comprising an upper part with a scanning zone and a circular central opening, along with a lower part featuring a sensor and a martyr graphite plate to capture and dissipate laser energy, allowing for precise determination of the laser beam's position by measuring energy transmission and reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing detection methods are used for low-power lasers, then detection is feasible, but they are not effective for high-power laser beams
Solution Approach 1:
The patent changes the detection parameters by introducing a calibrated hole with diameter matching the laser beam diameter, and using a martyr plate material that can withstand high power densities. This allows the detection system to adapt from low-power to high-power laser beams by modifying the interaction parameters rather than the fundamental detection mechanism.
Solution Approach 2:
The patent introduces an intermediary calibrated hole and martyr plate system between the high-power laser beam and the sensor. This intermediary structure enables the sensor to detect laser position indirectly through energy transmission patterns, protecting the sensor from direct exposure to high-power beams while maintaining detection accuracy.
2Measurement precision
If the laser beam position is not precisely detected, then alignment accuracy deteriorates, but detection precision is difficult to achieve for immaterial beams
Solution Approach 1:
The patent utilizes the interaction of laser energy with the martyr plate material, which produces detectable signals (such as thermal radiation or light emission) when the laser beam interacts with it. This transforms the invisible immaterial laser beam into a detectable signal, enabling precise position measurement.
Solution Approach 2:
The patent replaces direct mechanical or optical interaction methods with an energy-based detection approach. By using the transmission and reflection of laser energy through the calibrated hole and interaction with the martyr plate, the system achieves precision measurement without requiring direct mechanical contact or complex optical paths.
3Loss of energy
If the laser beam energy is not properly dissipated, then energy loss occurs, but proper dissipation requires specialized components
Solution Approach 1:
The martyr plate serves multiple functions: it absorbs and dissipates laser energy, provides a reference surface for detection, and protects downstream components from excessive energy. This multi-functionality reduces the need for separate energy dissipation components, simplifying the overall device structure while effectively managing energy loss.
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 accurate positioning of the laser beam with an accuracy of approximately 50 µm, suitable for laser beams ranging from 1 to 1000 W, ensuring precise alignment and traceability in additive manufacturing processes.
Implementation Method 1
a sensor to capture part of the energy transmitted by the laser beam
Implementation Method 2
a martyr graphite plate to absorb the remaining part of the energy transmitted by the beam laser
Implementation Method 3
the first and the second element being configured so that the reflections of the laser beam between the first and the second element are endless to dissipate the energy from the laser beam
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
The invention relates to a device (100) for detecting the position of a laser beam (15) with a predetermined diameter and emitted by a laser of an additive manufacturing machine, said detection device (100) comprising an upper portion (102) comprising a scanning zone (108) of the laser beam (15), said scanning zone (108) comprising, at the centre thereof, a circular hole (111) with a diameter substantially equal to the diameter of the laser beam and with a predetermined position; the detection device (100) comprising a lower portion (103), the lower portion (103) comprising at least one sensor (114) for collecting a portion of the energy transmitted by the laser beam (15); so that when the laser beam (15) scans the scanning zone (108) from a plurality of positions, the sensor (114) collects a portion of the energy transmitted by the laser beam from each position, the portion of the transmitted energy being maximum when the laser beam (15) is aligned with the circular hole (111).