Laser Focal Position Correction Using Processing Mark Imaging
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Solution Overview
Problem
Laser processing devices face productivity issues due to the need for dedicated devices and skilled maintenance workers to correct focal positions of laser light, leading to downtime and decreased machining quality when the focal position deviates.
Innovation Solution
A laser processing device equipped with a camera, image processor, autofocus controller, and driver that automatically corrects the focal position of laser light by measuring the diameter of a processing mark formed on the workpiece, allowing the laser head to be adjusted to the optimal focal position without requiring a dedicated device or skilled maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated focus monitor and dedicated jig are used to measure beam diameter and correct focal position, then measurement precision is improved, but device complexity increases and productivity decreases due to requiring specialized equipment and skilled maintenance workers
Solution Approach 1:
The patent uses image processing to create a digital copy of the processing mark on the workpiece surface. By capturing an image of the processed area and analyzing the mark's diameter in the image data, the system obtains beam diameter information without requiring physical measurement devices. This copying approach replaces dedicated focus monitors and jigs with standard imaging equipment, reducing device complexity while maintaining measurement capability
Solution Approach 2:
The patent replaces mechanical measurement systems (dedicated focus monitor, dedicated jig, manual measurement tools) with an optical imaging and image processing system. The camera captures optical information of the processing mark, and software algorithms automatically calculate beam diameter from the image data. This substitution eliminates the need for specialized mechanical measurement equipment and skilled manual operation, reducing both device complexity and maintenance requirements
2Manufacturing precision
If manual adjustment by maintenance worker is performed to correct focal position, then manufacturing precision is improved, but productivity decreases due to processing interruption and skilled labor requirement
Solution Approach 1:
The patent implements an automatic feedback control system that performs self-correction of focal position. The system automatically captures images of processing marks, calculates beam diameter from image data, determines focal position deviation, and adjusts the laser head position without human intervention. This self-service mechanism eliminates the need for maintenance workers to manually adjust the system, allowing continuous operation and maintaining high productivity while ensuring processing quality through automatic precision correction
Solution Approach 2:
The patent establishes a closed-loop feedback system where the actual processing mark diameter is measured via image processing, compared against the target diameter, and used to automatically adjust the focal position. The system continuously monitors processing quality through image capture and makes real-time corrections by moving the laser head or optical components. This automatic feedback loop maintains manufacturing precision without interrupting production, as the system self-corrects during or between processing operations
3Adaptability or versatility
If laser head is replaced, then adaptability is improved, but reliability decreases due to focal position deviation and subsequent processing quality deterioration
Solution Approach 1:
The patent implements preliminary calibration and measurement capabilities that are always ready and can be executed quickly after laser head replacement. The system includes pre-programmed image capture sequences and automatic analysis algorithms that immediately measure the new laser head's focal characteristics. By having the measurement and correction system prepared in advance and automatically executable, the system minimizes the impact of laser head replacement on reliability, allowing rapid adaptation to new components without prolonged processing quality issues
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 automatic correction of the focal position, reducing downtime and maintaining processing quality without the need for specialized equipment or personnel, thereby improving productivity.
Implementation Method 1
a camera that acquires surface image of a processing member that has been irradiated with the laser light
Implementation Method 2
a laser head that emits laser light
Implementation Method 3
laser light that has been condensed at a predetermined focal position by a condenser lens
Data Source
AI summary
The laser processing device includes a laser head that emits laser light and a camera that acquires a surface image of a processing member after being irradiated with the laser light. The laser processing device further includes an image processor that performs image processing on an acquired surface image and calculates a diameter of a processing mark, and an autofocus controller that derives an optimum focal position of the laser light based on the diameter of the processing mark. In addition, the laser processing device includes a driver that moves the laser head in an emission direction of the laser light to allow the laser light to be condensed at an optimum focal position based on the derivation result of the autofocus controller.