Laser Machining Calibration Using Reference Marks
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Solution Overview
Problem
The existing calibration methods for laser machining, such as the guess-and-check method, are inefficient and lack consistency, especially in production runs where precision and efficiency are crucial, particularly when dealing with small work pieces and tools.
Innovation Solution
A calibration method and system that involves locating a focal point of a laser relative to reference datums in a workspace, machining reference marks on a work piece, and measuring offsets using a detection device and monitor to accurately position the work piece in three dimensions, allowing for efficient and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the guess-and-check calibration method is used, then the work piece can be located relative to the reference datum, but numerous iterations are required which reduces efficiency and productivity
Solution Approach 1:
The patent applies preliminary action by pre-marking the work piece with reference marks at known locations before calibration. This allows the laser to directly target these pre-defined marks instead of requiring iterative guess-and-check positioning, significantly reducing the number of calibration iterations needed while maintaining precision.
Solution Approach 2:
The patent uses reference marks as simplified copies or representations of the work piece features. By creating these marks at known locations, the system can work with these simplified targets during calibration rather than directly manipulating the complex work piece geometry, improving efficiency.
2Measurement precision
If the work piece is removed between iterations for microscopic examination, then reference mark locations can be accurately measured, but the calibration process time increases
Solution Approach 1:
The patent performs preliminary marking of reference points on the work piece before the calibration iterations begin. This pre-preparation eliminates the need to remove and re-examine the work piece during each iteration, as the reference marks are already in place and can be directly targeted by the laser.
Solution Approach 2:
The patent introduces reference marks as intermediary elements that serve as proxies for the actual work piece features. These marks can be easily detected and measured without requiring removal of the work piece, acting as intermediaries that simplify the measurement process and reduce cycle time.
3Reliability
If iterative calibration is performed to ensure consistency in production runs, then machining precision is maintained, but the process becomes complex and time-consuming
Solution Approach 1:
The patent establishes reference marks at known locations before production runs begin. This preliminary setup creates a stable reference framework that can be reused across multiple production runs, ensuring consistency without requiring complex iterative calibration procedures for each run.
Solution Approach 2:
The reference marks serve multiple functions: they establish the coordinate system, provide targets for laser positioning, and enable verification of consistency across production runs. This multi-functionality reduces the need for separate calibration procedures, simplifying the overall process while maintaining reliability.
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 reduces the number of iterations required for calibration, enhances precision, and simplifies the mapping of work piece surfaces, thereby improving the efficiency and consistency of the laser machining process.
Implementation Method 1
the laser welder emits a laser beam to burn a hole in the metal sheet at a position, corresponding to a predetermined focal point of the laser welder
Implementation Method 2
a metal sheet is placed on the positioning table under the laser welder, and the laser welder emits a laser beam to burn a hole in the metal sheet at a position, corresponding to a predetermined focal point of the laser welder
Data Source
AI summary
A calibration method is disclosed. The method includes locating a focal point of a laser relative to at least one reference datum of a workspace, the focal point being where the laser produces machining. The method also includes machining at least one reference mark onto a work piece via the laser machining at the focal point and measuring an offset between a reference point on the work piece and the at least one reference mark.