Laser Beam Test Sensor for Reproducible Fiber Optic Alignment
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Solution Overview
Problem
The adjustment of laser devices for processing optical waveguides is an iterative and non-reproducible process, requiring significant experience and involving complex procedures for commissioning and maintenance, with unsatisfactory welding results often necessitating repositioning and recalibration.
Innovation Solution
A portable test device equipped with a sensor to detect contour coordinates, light intensity, and intensity distribution, coupled with an electronic evaluation unit that adjusts the laser device's position and alignment based on objective data, facilitating rapid and precise adjustments and enabling on-site testing and calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual verification of laser dot position using sample welding results is performed, then the laser device can be adjusted, but the adjustment process becomes iterative and non-reproducible requiring high experience level
Solution Approach 1:
The patent replaces manual visual inspection and mechanical adjustment with an automated optical measurement system. A sensor detects the actual laser dot position and coordinates are automatically compared with target values, eliminating the need for iterative visual verification and manual repositioning by experienced operators.
Solution Approach 2:
The system implements automated feedback by detecting the actual laser dot position, comparing it with target coordinates, and providing guidance for adjustment. This closed-loop feedback mechanism enables reproducible adjustments without requiring operator experience, directly resolving the contradiction between measurement precision and procedure complexity.
2Ease of repair
If the laser system is removed for maintenance or inspection, then system components can be examined, but complex procedures are required to restore the system to operational readiness
Solution Approach 1:
The patent enables preliminary documentation of laser system parameters before maintenance. By recording the actual laser dot coordinates and system configuration prior to removal, the system can be quickly restored to its original state after maintenance without requiring complex restoration procedures, thus reducing downtime while maintaining ease of repair.
3Ease of operation
If iterative adjustment process is used for commissioning, then laser device can be set up, but the process requires high experience level and is not reproducible
Solution Approach 1:
The patent replaces subjective manual adjustment with objective automated measurement and comparison. The sensor system objectively determines laser dot position and compares it with pre-defined target coordinates, eliminating dependence on operator experience and ensuring reproducible setup results across different operators and installations.
Solution Approach 2:
The system transforms the commissioning process from subjective visual assessment to objective parameter-based adjustment. By measuring and comparing specific parameters (laser dot coordinates) against target values, the system ensures reproducible setup while simplifying the operation for less experienced users.
4Manufacturing precision
If no automated testing device is used, then the system structure remains simple, but welding quality cannot be objectively compared to target specification
Solution Approach 1:
The patent implements automated feedback by detecting the actual laser dot position and comparing it with target coordinates. This objective measurement and comparison system enables precise control of welding quality while the portable design keeps the added complexity manageable. The sensor system provides quantitative data for quality assessment rather than subjective visual inspection.
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 simplifies and makes the adjustment process reproducible, reduces commissioning and maintenance time, enhances product quality by objective comparison to a target specification, and allows for documentation of processing quality, while enabling on-site evaluation and adjustment of laser processing devices.
Implementation Method 1
the sensor is configured to detect contour coordinates, light intensity, and intensity distribution
Data Source
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AI summary
The invention relates to a test device (10) for a laser processing device (100) or a calibration station. The test device (10) comprises a housing (11) with a window section (13), wherein the housing (11) can be inserted into a laser processing device (100), a sensor received in the housing (11) for detecting a laser beam (S) guided through the window section (13), and a transmission device (12) for transmitting data from the sensor to an evaluation unit.