Laser Calibration Grid Pattern for Secure Token Marking
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Solution Overview
Problem
Conventional methods for calibrating the orientation of an etching laser are tedious, error-prone, and limit throughput, especially in mass-producing objects with individualized markings like secure tokens, due to manual measurement of deviations which are time-consuming and costly.
Innovation Solution
The method involves projecting and marking a grid pattern on a calibration object, allowing for accurate measurement of misalignment in two orthogonal directions and rotation, enabling automatic machine vision offset calculations to correct the laser mark's position and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual measurement of deviation is used to calibrate laser orientation, then the calibration can be performed with simple equipment, but the process becomes tedious and error-prone
Solution Approach 1:
A calibration object with a grid pattern and reference image serves as an intermediary between the laser marking system and the measurement process. The grid provides precise reference lines for measuring deviation in X and Y directions, while the reference image indicates the desired mark location. This intermediary enables accurate measurement without requiring complex measurement equipment or procedures.
Solution Approach 2:
The calibration object creates a visual copy or representation of the marking system's actual performance by displaying the test mark position relative to the grid and reference image. This visual copy allows operators to accurately determine deviation by comparing the test mark location with the expected location indicated by the reference image and grid lines.
2Ease of manufacture
If manual measurement of deviation is used for calibration, then equipment costs remain low, but throughput is limited and manufacturing costs increase
Solution Approach 1:
The grid-patterned calibration object acts as a mediator that enables rapid assessment of laser positioning accuracy. By providing pre-marked reference lines and a reference image, it allows operators to quickly determine deviation in both X and Y directions without time-consuming measurement procedures, thereby increasing calibration throughput while keeping equipment simple.
Solution Approach 2:
The calibration object is prepared in advance with a grid pattern and reference image already marked on it. This preliminary action eliminates the need for complex measurement equipment during calibration, as the reference framework is already in place. The object can be reused multiple times, increasing productivity while maintaining low equipment costs.
3Loss of time
If estimation of misalignment distance is used, then the calibration process is quick, but accuracy is compromised
Solution Approach 1:
The grid pattern on the calibration object serves as an intermediary measurement scale that enables rapid yet accurate determination of misalignment distance. The reference lines provide clear visual cues for measuring deviation in X and Y directions, allowing operators to quickly and accurately assess the test mark position relative to the desired location indicated by the reference image.
Solution Approach 2:
The calibration object transforms the abstract concept of misalignment into measurable parameters by providing a grid with known dimensions and spacing. This allows the misalignment distance to be determined by counting grid units or measuring distances along the grid lines, converting a potentially time-consuming estimation into a quick and accurate measurement process.
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 approach significantly improves the accuracy and speed of laser marking system calibration, reducing human error and manufacturing costs by enabling fast, precise alignment of laser marks using grid-based measurements.
Implementation Method 1
a laser such as a carbon dioxide laser with sufficient power to burn a hole in the object's surface irradiates a template of the marking on a portion of the object
Implementation Method 2
the laser etches the marking in the object... the laser burns the marking
Data Source
AI summary
An improved technique for calibrating the location of an individualized marking includes marking both a grid and an image on a calibration object. The technique uses the marked grid to measure the distance in two orthogonal directions from the current image location to the desired image location by counting the number of grids between the current image location to the desired image location.