Laser-Fluid Jet Nozzle Alignment Using Reflected Light Patterns
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Solution Overview
Problem
Conventional apparatuses for machining workpieces with laser beams coupled into fluid jets face challenges in accurately and efficiently aligning the laser beam with the nozzle aperture, due to time-consuming and error-prone manual methods, especially with dot contaminations on the nozzle.
Innovation Solution
An automatic laser-nozzle alignment system that uses optically sensed laser beam reflections and computational evaluation to determine precise alignment, employing a control unit, sensing unit, and optical unit to detect and distinguish reflected light patterns, allowing for real-time control of the laser beam's position and incidence on the nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment method is used to align laser beam with nozzle aperture, then alignment can be performed, but alignment time is long and alignment precision is low
Solution Approach 1:
The patent replaces manual mechanical alignment with an automatic optical sensing and control system. The sensing unit detects reflected laser light patterns from the nozzle aperture, and the control unit processes these signals to automatically adjust the laser beam position, eliminating manual intervention and significantly reducing alignment time while improving precision.
Solution Approach 2:
The patent implements a feedback mechanism where the sensing unit continuously monitors the reflected laser light from the nozzle aperture, provides sensing signals to the control unit, which then adjusts the laser beam position accordingly. This closed-loop feedback system enables precise and rapid automatic alignment.
2Difficulty of detecting and measuring
If defocused laser beam is used to illuminate entire nozzle for visual identification, then bore position can be located, but dot contaminations cause false detection and alignment errors
Solution Approach 1:
The patent uses a focused laser beam that creates a localized bright spot pattern on the nozzle surface, rather than illuminating the entire nozzle. The sensing unit detects specific local reflection patterns that are characteristic of the aperture, enabling differentiation between the aperture and contaminations based on their distinct local optical properties.
Solution Approach 2:
The patent utilizes optical contrast differences - the focused laser beam creates distinct brightness patterns when reflecting from the aperture versus contaminations. The sensing unit detects these optical property differences, allowing reliable identification of the aperture position without being misled by contaminations that have different reflection characteristics.
3Measurement precision
If focused laser beam is used for alignment, then alignment precision improves, but the ability to locate bore position becomes more difficult due to concentrated light
Solution Approach 1:
The patent transitions from direct visual observation of the focused beam to indirect detection through reflected light patterns captured by the sensing unit. By measuring the spatial distribution and intensity of reflected light, the system can precisely locate the aperture position and achieve accurate alignment without the limitations of direct visual inspection.
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 fast and precise automatic alignment of the laser beam with the nozzle aperture, reducing errors and alignment time, while distinguishing between nozzle apertures and contaminations for accurate detection.
Implementation Method 1
a sensing unit configured to sense laser light reflected from a surface of the nozzle unit and produce a sensing signal based on the sensed reflected laser light
Implementation Method 2
the laser beam is guided in the fluid jet onto the workpiece by means of total internal reflection
Data Source
AI summary
The invention relates to an apparatus 100 for machining a workpiece with a laser beam 101 coupled into a fluid jet. The apparatus 100 comprises a laser unit 101a for providing the laser beam 101, a nozzle unit 102 with an aperture 102a for producing the fluid jet, and an optical unit 103 configured to provide the laser beam 101 from the laser unit 101a onto the nozzle unit 102. Further, the apparatus 100 comprises a control unit 104 configured to control 108, 110 the optical unit 103 and/or nozzle unit 102 to change a point of incidence 109 of the laser beam 101 on the nozzle unit 102. The apparatus 100 also comprises a sensing unit 105 configured to sense laser light 106 reflected from a surface 102b of the nozzle unit 102 and produce a sensing signal 107 based on the sensed reflected laser light 106. The control unit 104 is particularly configured to evaluate the sensing signal 107 and to determine a defined sensing pattern in the sensing signal 107 indicative of the laser beam 101 being fully and/or partially aligned with the aperture 102a.