Laser Engraver Calibration Using Shared Camera-Laser Optics
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Solution Overview
Problem
Laser engraver systems face challenges in maintaining high position precision over long periods due to drift and instability, making it difficult to achieve accurate alignment of engraved features, especially when requiring accuracy of 10 μm or less over a 120 mm field without costly and complex mechanical constructions.
Innovation Solution
A laser engraver system that calibrates the camera and laser using a reference grid on a plate, where the optical paths of both the laser and camera coincide, allowing the controller to determine and correct misalignments by comparing theoretical and actual positions of engraved patterns, enabling recalibration 'on the fly' without calibration cards or test products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If special mechanical constructions and very stable components are used to achieve high position accuracy of 10 μm or less over a 120 mm field, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical stability solutions with a software-based calibration system. The camera captures images of the reference grid, and computational algorithms calculate transformation parameters to compensate for misalignments between laser and camera optical paths. This substitutes mechanical precision requirements with optical measurement and mathematical correction.
Solution Approach 2:
The system dynamically adjusts calibration parameters (translation, rotation, scaling) based on captured reference grid images. These parameter changes compensate for drift and misalignment without requiring mechanical re-adjustment, allowing the system to maintain precision through software updates rather than mechanical modifications.
2Reliability
If special mechanical constructions and very stable components are used to maintain alignment stability over long periods, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The system implements continuous feedback through periodic calibration using the reference grid. The camera repeatedly captures the reference grid pattern, and the system calculates current alignment deviations, comparing them against reference values to detect drift and trigger recalibration when necessary.
Solution Approach 2:
The calibration system is self-correcting, automatically detecting and compensating for its own drift without external intervention. The reference grid embedded in the workpiece or plate serves as an internal reference that the system uses to self-diagnose and self-correct alignment issues.
3Manufacturing precision
If calibration cards are used to calibrate the laser and visual system, then manufacturing precision is improved, but loss of time increases due to repeated calibration steps
Solution Approach 1:
The patent merges the calibration reference directly into the workpiece or mounting plate by embedding the reference grid pattern. This eliminates the need for separate calibration cards and external calibration procedures, integrating the calibration function into the operational workflow.
Solution Approach 2:
The reference grid is continuously available during normal operation, allowing calibration to occur at any time without interrupting the workflow. The system can perform quick reference grid captures and recalculations on-demand, maintaining calibration without dedicated calibration steps.
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 solution ensures precise alignment and quality of engraved images over time, reducing the need for special mechanical stability and frequent recalibration, while maintaining high accuracy without additional calibration steps or elements.
Implementation Method 1
a laser and a camera and a plate for holding a product to be engraved, the plate comprising a reference grid, wherein an optical path of the laser is directed to the plate
Implementation Method 2
an optical path of the camera is directed to the plate and the optical path of the camera to the plate and the optical path of the laser to the plate are at least partially the same before and when hitting the plate
Data Source
AI summary
A laser engraver having a laser, a camera, and a plate for holding a product, wherein an optical path of the laser is directed to the plate, an optical path of the camera is directed to the plate, and the optical path of the camera to the plate and the optical path of the laser to the plate are at least partially the same before and when hitting the plate. The laser engraver includes a controller and a comparator, wherein the controller is configured to have the laser engrave a predefined pattern at a predefined position on the product on the plate to form an engraved pattern on the product and have the camera capture a position of the engraved pattern, have the comparator compare the predefined position and the position captured by the camera to determine a difference therebetween, and use the difference to calibrate the laser.