Laser Beam Calibration Using Sensor Fields and Plate Gauge
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Solution Overview
Problem
Existing laser calibration methods in additive manufacturing lack the ability to freely position a working laser beam with high accuracy and reproducibility, limiting the efficiency and quality of component production.
Innovation Solution
A device and method using a sensor plate with multiple sensor fields and a perforated plate gauge to calibrate laser devices, allowing precise alignment of laser beams relative to each other, utilizing a pilot laser beam to determine and correct deviations, and establishing a common coordinate system for multiple processing heads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing laser calibration methods are used, then the calibration process is simple, but the positioning accuracy and reproducibility of the laser beam are insufficient
Solution Approach 1:
A sensor plate is introduced as an intermediary component between the laser beam and the calibration system. The sensor plate contains multiple sensor fields that detect the laser beam position, enabling precise measurement without requiring complex direct measurement apparatus. This intermediary device translates the laser beam position into detectable signals while maintaining system simplicity.
Solution Approach 2:
The patent replaces traditional mechanical alignment and measurement methods with an optical sensing system. Instead of using mechanical gauges or physical alignment tools, the system uses sensor fields on a sensor plate to detect laser beam position optically, achieving higher precision without mechanical complexity.
2Adaptability or versatility
If a single sensor field is used for calibration, then the device complexity is low, but the ability to freely position and calibrate multiple laser beams relative to each other is limited
Solution Approach 1:
The sensor plate is divided into multiple sensor fields, each capable of detecting laser beam positions independently. This segmentation allows multiple laser beams to be calibrated simultaneously or sequentially with high precision, as each sensor field can track a specific beam or region. The modular sensor field structure enables versatile multi-beam calibration while keeping individual sensor fields relatively simple.
3Manufacturing precision
If high-precision calibration is performed without a common coordinate system, then individual laser beam accuracy is high, but the relative positioning accuracy between multiple laser beams deteriorates
Solution Approach 1:
Multiple sensor fields are merged into a single sensor plate that establishes a common coordinate system. This unified coordinate system allows the relative positions of multiple laser beams to be determined with high accuracy, as all beams are referenced to the same coordinate framework provided by the sensor plate. The merging of sensor fields into one integrated plate simplifies coordinate management compared to using separate calibration systems for each beam.
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 high-resolution, precise calibration of laser beams, improving the reproducibility and quality of additive manufacturing processes by ensuring accurate positioning of laser beams relative to each other, enhancing production efficiency and component quality.
Implementation Method 1
sensor plate (3) and a perforated plate gauge (4)... sensor fields (5)... determining the relative position of the sensor fields (5) to one another... positioning a pilot laser beam on the sensor fields
Data Source
Figure 1~3
AI summary
According to the invention, a device (1) is provided for calibrating a laser device, which device is designed to freely position a working laser beam in a predetermined working area. Said device comprises a sensor plate (3) having one or more sensor fields (5) for arrangement in a working area, a perforated plate gauge (4) with one or more calibration passage openings (6), wherein the at least one or more calibration passage openings (6) are in each case arranged in the region of the at least one or more sensor fields (5), a pilot laser device for providing a pilot laser beam along the beam path of the working laser beam in order to calibrate a laser device.