Laser Beam Coupling for Direction-Independent Seam Tracking
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Solution Overview
Problem
Existing laser machining systems, such as those used for welding, face challenges in achieving directionally independent seam tracking, as most methods are limited to predefined welding directions and lack flexibility in following seam progressions, especially in robot-guided processes.
Innovation Solution
A laser machining system incorporating first and second deflection optics with independent mirrors for two-dimensional motion of the machining and measuring beams, respectively, and a coupling device like a beam splitter for coaxial superimposition, enabling precise seam tracking and measurement independent of machining direction using optical short-coherence tomography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If light-section methods with laser line projection are used for seam detection, then seam position can be determined, but the method is limited to predefined welding directions and lacks directional independence
Solution Approach 1:
The patent divides the beam path into separate channels: the machining laser beam path and the measuring beam path. By segmenting the optical paths and using independent deflection optics for each beam, the system enables the measuring beam to scan independently in any direction while the machining laser follows the seam progression, thereby achieving directional independence in seam detection
Solution Approach 2:
The patent introduces a coupling device (beam splitter) as an intermediary element that allows the measuring beam to be coupled into the machining laser beam path. This intermediary component enables both beams to share the same optical path while maintaining independent control, allowing the measuring beam to perform directional-independent scanning without interfering with the machining process
2Adaptability or versatility
If the entire optics are co-rotated to follow seam progression, then directional independence is partially achieved, but the solution is only feasible to a limited degree in robot-guided processes
Solution Approach 1:
Instead of rotating the entire optics assembly, the patent segments the deflection control by providing separate deflection optics for the machining laser and the measuring beam. This allows independent angular control of each beam without mechanical rotation of the complete optics, reducing device complexity while maintaining directional independence
Solution Approach 2:
The patent replaces the mechanical rotation of entire optics with independent optical deflection mechanisms (deflection mirrors or acousto-optic deflectors) for each beam. This substitution eliminates the need for complex mechanical rotation assemblies while achieving the same functional outcome of directional independence
3Adaptability or versatility
If separate deflection optics with independent mirrors are used for machining and measuring beams, then directional independence is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the machining laser beam path and the measuring beam path using a coupling device, allowing both beams to propagate through the same optical path after separation. This merging reduces the need for separate optical paths and minimizes the total number of optical elements required, thereby reducing device complexity while maintaining independent beam control
Solution Approach 2:
The patent designs the optical system with universal components that serve multiple functions: the beam splitter couples both beams while allowing independent deflection, and the shared optical path after coupling reduces redundancy. This multi-functionality approach minimizes the number of dedicated components for each beam, reducing overall device complexity
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 solution allows for high-resolution, directionally independent seam detection and precise positioning of the laser beam, achieving an accuracy of about 1 μm, significantly improving upon traditional light-section methods which are limited by line projection quality.
Implementation Method 1
The first deflection optics preferably comprise two independent first deflection mirrors
Implementation Method 2
The second deflection optics preferably comprise two independent second deflection mirrors
Implementation Method 3
The coupling device is preferably a beam splitter. The coupling device is typically designed for essentially superimposing the machining laser beam and the measuring beam coaxially
Implementation Method 4
as well as a corresponding laser machining method, by means of which precise seam tracking can be realized independently of a machining direction
Data Source
AI summary
The invention pertains to a laser machining system includes first deflection optics, second deflection optics, and a coupling device. The first deflection optics deflect a machining laser beam in two directions in space. The second deflection optics deflect a measuring beam in two directions in space independently of the machining laser beam. The coupling device is arranged in a beam path of the machining laser beam and couples the measuring beam into the beam path of the machining laser beam.