Laser Engraver Calibration System Using Vision-Based Comparison
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Solution Overview
Problem
The existing calibration methods for laser engravers are time-consuming and labor-intensive, requiring manual adjustment of multiple machines to achieve identical results, and do not efficiently account for variations in grey levels, size, and marking distance, leading to inefficiencies in precision and consistency.
Innovation Solution
A system comprising a marking system with a focusing lens and a vision system connected to a comparison device, using a calibration card with varying parameters to automatically adjust and verify the alignment and settings of laser engravers, allowing for precise calibration of grey levels, size, and marking distance through data comparison and iterative adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration methods are used with successive test cards, then adjustment precision can be achieved, but calibration time and effort increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-defining multiple test patterns with different parameters (grey levels, sizes, marking distances) on a single calibration card before the calibration process begins. This allows the vision system to capture and analyze all necessary calibration data in one shot, eliminating the need for successive test cards and manual iterative adjustments, thereby significantly reducing calibration time while maintaining precision.
Solution Approach 2:
The patent uses a vision system with a camera to capture an optical copy/image of the calibration card patterns. This digital copy is then processed by a comparison device that compares measured parameters against reference values stored in memory. This copying and digital comparison approach replaces time-consuming manual measurements and iterations with automated optical measurement and computational analysis.
2Manufacturing precision
If manual adjustment is performed for each laser engraver, then individual calibration can be achieved, but effort and complexity increase when adjusting multiple machines
Solution Approach 1:
The patent creates a universal calibration card with standardized test patterns that can be used to calibrate multiple laser engravers with different parameters (grey levels, sizes, marking distances) in a single operation. The vision system and comparison device provide multi-functional automated measurement and analysis capabilities, replacing multiple manual adjustment procedures with one unified calibration process that works across different machines.
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated vision system and computer-based comparison device. The camera captures calibration data, the processor analyzes the images, and the system automatically determines optimal settings, eliminating the need for operators to manually adjust each laser engraver through trial and error with physical test cards.
3Manufacturing precision
If calibration parameters are not comprehensively measured, then calibration process is simpler, but precision and consistency of laser engraving deteriorate
Solution Approach 1:
The patent segments the calibration card into multiple distinct test patterns, each designed to measure specific calibration parameters independently (grey level patterns, size patterns, marking distance patterns). The vision system captures all segments simultaneously, and the comparison device analyzes each segment to extract the corresponding parameter measurements, ensuring comprehensive calibration coverage through systematic segmentation of the measurement task.
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 system significantly reduces calibration time and effort, enabling precise and identical adjustments across multiple laser engravers, improving precision and consistency by automating the calibration process and using a calibration card with defined patterns to measure and adjust parameters.
Implementation Method 1
the plastic card being made of at least one changing color component according to the energy provided by the laser marker
Implementation Method 2
the vision system including a camera associated with an appropriate illumination
Data Source
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AI summary
The present invention concerns a system for the calibration of at least one parameter of a laser engraver, the laser engraver comprising on one hand an engraving system with a focusing lens positioned at a distance of the surface of an substrate intended to be engraved and on the other hand a vision system for at least the positioning and the verification of the engraving, the vision system including a camera associated with an appropriate illumination and, wherein the engraving device of the laser is arranged in such way that the engraving device works to engrave a substrate with specific engraved layout corresponding to variation of at least one parameter and wherein the vision system is connected to a comparison device of at least one measured engraved parameter with the template value of at least one stored data in a memorisation device connected to a engraving correction device.