Laser Focus Correction for Misaligned 3D Workpiece Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser processing apparatuses face challenges in maintaining high processing accuracy when dealing with workpieces of varying heights, as the focal position of laser light deviates between the center and edges during two-dimensional scanning, leading to misalignment and reduced precision.
Innovation Solution
A laser processing apparatus that includes an imaging section for capturing the workpiece, a setting section for identifying correction areas and distance measurement positions, a storage section for image information, and a position correction section to adjust the focal position based on measured misalignment, ensuring accurate alignment and scanning control for maintaining high processing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If two-dimensional scanning using a galvano mirror is performed, then the processing area can be covered, but the focal position deviates from the processing area at the edges
Solution Approach 1:
The patent transitions from two-dimensional scanning to three-dimensional scanning by adding Z-axis movement capability. The laser processing head can move along the Z-axis to adjust the focal position dynamically, ensuring the focal point remains at the correct depth regardless of the lateral position within the processing area. This dimensional addition resolves the focal position deviation problem at edges while maintaining comprehensive area coverage.
Solution Approach 2:
The system implements dynamic focal position adjustment during scanning operations. Instead of using a fixed focal position, the laser processing head dynamically changes its Z-position based on the scanning location and workpiece surface topography. This dynamic adaptation ensures consistent focal accuracy across the entire processing area, eliminating the edge deviation issue present in static two-dimensional scanning systems.
2Adaptability or versatility
If laser processing is performed on workpieces with height variations, then the processing capability is expanded, but the processing accuracy decreases
Solution Approach 1:
The system dynamically adjusts the focal position in real-time during scanning operations. The laser processing head moves along the Z-axis to track workpiece surface variations, maintaining optimal focal distance regardless of height changes. This dynamic focal tracking enables the system to process workpieces with significant height variations while preserving high processing accuracy throughout the entire workpiece surface.
Solution Approach 2:
The imaging section continuously monitors workpiece surface topography and provides feedback to the control system. Based on this feedback, the system automatically adjusts the focal position to match the local surface height. This feedback-driven adaptive focusing maintains consistent processing accuracy across workpieces with varying heights, transforming the system from a height-sensitive device to a height-adaptive processing system.
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
The apparatus effectively corrects misalignment and maintains high processing accuracy by adjusting the focal position and scanning control, ensuring precise laser processing even on workpieces with height variations.
Implementation Method 1
a laser light output section that generates laser light based on the excitation light generated by the excitation light generation section and emits the laser light
Implementation Method 2
a focus adjustment section that adjusts a focal position of the laser light emitted from the laser light output section
Implementation Method 3
an imaging section that captures the workpiece to generate a captured image including at least a part of the processing area
Data Source
AI summary
High processing accuracy of a workpiece is maintained even if the workpiece is misaligned. A laser processing apparatus includes: a setting section that sets a pattern area and a distance measurement position on a captured image; a condition setting storage section that stores image information in the pattern area; a position correction section that detects a misalignment of a new workpiece different from a workpiece used to set the pattern area and corrects the distance measurement position on the new workpiece; a distance measurement section that measures a distance based on a light reception position of distance measuring light in a distance measuring light receiving section; and a Z scanner that adjusts a focal position based on a measurement result of the distance measurement section prior to irradiation of the workpiece with laser light.