Laser Module Calibration Using Visible-Light Spot Triangulation
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Solution Overview
Problem
Current consumer or desktop laser cutting devices face challenges in accurately obtaining laser cutting parameters, leading to low precision and requiring excessive manual intervention, which restricts their application due to complex parameter acquisition processes.
Innovation Solution
A method and system for calibrating laser processing devices using a visible-light emitter and a camera module, where the laser module is positioned at different heights to capture light spots and calculate the actual distance to the material using the theorem of similar triangles, allowing for automatic calibration and parameter determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual intervention is used to acquire laser cutting parameters, then the process can be completed with simple equipment, but the precision is low and the operation is complex
Solution Approach 1:
The system uses the laser module itself as the light source for calibration, eliminating the need for separate calibration equipment. The laser module projects light spots and the camera module captures them, allowing the device to calibrate itself automatically without external tools or complex manual procedures
Solution Approach 2:
The patent replaces manual mechanical measurement methods with an optical system. Instead of physically measuring distances with tools, the system uses laser projection and camera imaging to automatically determine calibration parameters through optical path analysis
2Ease of operation
If automated calibration is implemented, then operator convenience is enhanced and operations are simplified, but device complexity increases due to additional components
Solution Approach 1:
The camera module is integrated with the laser module, merging two functions (laser projection and image capture) into a single integrated unit. This reduces the number of separate components and simplifies the overall system structure while enabling automated calibration
Solution Approach 2:
The visible-light emitter serves dual purposes: it acts as both a calibration light source and works in conjunction with the camera module for normal operation. The camera module both captures calibration data and can be used for monitoring processing, providing multi-functionality that justifies the added complexity
3Measurement precision
If multiple reference stages are used in optical coherence tomography, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential calibration function from complex optical measurement systems. Instead of using full optical coherence tomography with multiple reference stages, it uses a simplified approach with a single visible-light emitter and camera module that captures light spot positions to calculate calibration parameters
Solution Approach 2:
The system uses consumer-grade camera modules and standard laser diodes instead of expensive precision optical equipment. These components are readily available, cost-effective, and sufficient for achieving the required calibration accuracy in consumer and desktop laser cutting devices
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 reduces mechanical and environmental errors, enhances operator convenience, and simplifies operations by providing automated calibration, increasing reliability and precision in laser cutting processes.
Implementation Method 1
positioning the laser module at a first height from the work platform, and capturing with the camera module an image of a first light spot projected on the work platform by the visible-light emitter
Implementation Method 2
obtaining a conversion formula of an actual distance hx from the laser module to a surface of the material to be processed which is placed on the work platform according to theorem of similar triangles
Data Source
AI summary
A system and a method for calibrating laser processing parameters comprises positioning a laser module at a first height from a work platform, capturing with a camera module an image of a first light spot projected on the work platform by a visible-light emitter to obtain a first position data of the first light spot on an image plane of a lens of the camera module at the first height; positioning the laser module at a second height from the work platform different from the first height, capturing with the camera module an image of a second light spot projected on the work platform by the visible-light emitter to obtain a second position data of the second light spot on an image plane at the second height, obtaining a conversion formula of an actual distance, and plugging the first and second position data into the conversion formula.