Laser Processing Machine Optical Axis Calibration Feedback
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Solution Overview
Problem
Existing laser processing machines face challenges in accurately calibrating the irradiation position of a laser beam due to errors caused by rotational positioning errors of mirrors and optical distortion, requiring time-consuming and precise microscope examinations for correction.
Innovation Solution
A laser processing machine that incorporates a camera sensor with a beam splitter on the optical path to capture images of a grid pattern on the workpiece surface, allowing for accurate detection and correction of errors between the target and actual irradiation positions, enabling easy calibration without the need for microscope examination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a galvano scanner and condensing lens are used to displace the optical axis of the laser beam, then the laser beam can be directed to freely-selected positions on the workpiece, but errors in the plane coordinate system are caused due to rotational positioning errors and optical distortion
Solution Approach 1:
The patent employs a camera to capture the actual position of the laser spot on the workpiece and feeds this information back to the control unit. The control unit compares the instructed position with the actual captured position and automatically calculates and applies correction values to the galvano scanner instructions, forming a closed-loop feedback system that eliminates coordinate system errors.
Solution Approach 2:
The patent replaces manual microscope-based measurement and correction with an automated optical measurement system using a camera. The camera captures images of the laser spot position, and the control unit automatically processes this visual information to determine correction values, substituting mechanical measurement methods with optical detection and automated computation.
2Measurement precision
If microscope examination is used to measure errors on test patterns, then accurate correction can be obtained, but the process becomes very time consuming and requires high precision microscope equipment
Solution Approach 1:
The patent replaces the mechanical microscope measurement system with an automated camera-based optical measurement system. The camera captures the laser spot position directly during or after processing, and the control unit automatically calculates correction values from the captured images, eliminating the need for time-consuming manual microscope examination while maintaining measurement accuracy.
Solution Approach 2:
The system performs self-measurement and self-correction by using the camera to automatically capture the laser spot position and the control unit to automatically calculate and apply correction values. This eliminates the need for external microscope equipment and manual measurement operations, allowing the system to correct its own positioning errors autonomously.
3Manufacturing precision
If correction operation is performed by adding correction amounts to instruction values, then the irradiation position accuracy is improved, but the operation becomes troublesome when optically adjusting the laser oscillator or exchanging the condensing lens
Solution Approach 1:
The patent implements automatic feedback correction where the camera continuously monitors the laser spot position and the control unit automatically adjusts the instruction values based on captured position information. This eliminates the need for manual correction operations when adjusting the laser oscillator or exchanging lenses, as the system automatically compensates for any positional deviations.
Solution Approach 2:
The system performs automatic self-correction by using the camera to detect position errors and the control unit to automatically calculate and apply correction values to the galvano scanner instructions. This eliminates the need for troublesome manual correction operations during optical adjustments or component exchanges, making the system easier to operate.
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 rapid and precise calibration of the laser beam irradiation position, reducing the need for microscope-based corrections and improving the accuracy of laser processing operations.
Implementation Method 1
a beam splitter 3 on the optical path to capture images of a grid pattern on the workpiece surface
Implementation Method 2
the image of the target irradiation position and its periphery in the predetermined surface is captured by the camera sensor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A processing machine is configured to include mirrors 112 and 122 to reflect a beam L oscillated from a laser oscillator to a predetermined surface 4 on which a workpiece is arranged, optical axis operating mechanisms 111 and 121 to position an optical axis of the beam L at a desired target irradiation position by changing directions of the mirrors 112 and 122, a camera sensor to capture an image of the target irradiation position and its periphery reflected in the mirror 122, and an error calibration mechanism to detect an error between the target irradiation position instructed to the optical axis operating mechanisms 111 and 121 and an actual position of the optical axis of the beam L in the predetermined surface 4 by referring to the image captured by the camera sensor. A correction amount to be instructed to the optical axis operating mechanisms 111 and 121 is determined based on the error in order to irradiate the target irradiation position with the beam L during processing.