Laser Head Calibration Using a Low-Power Beam Profiler
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Solution Overview
Problem
High-power beam profilers are expensive and cumbersome, making them impractical for routine calibration of laser processing machines, which necessitates a more cost-effective and space-efficient solution for monitoring and calibrating laser head parameters.
Innovation Solution
A system using a low-power pointer laser and imaging sensor, controlled by a controller, to calibrate laser processing machines by capturing images of the optical beam at various conditions, measuring parameters, and adjusting machine components for precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high-power beam profiler is used to measure laser head parameters, then measurement precision is improved, but device cost and space requirements increase significantly
Solution Approach 1:
The patent uses a low-power pointer laser to create a copy of the high-power laser beam path for measurement purposes. The pointer laser follows the same optical path through the laser head components, allowing the imaging sensor to capture beam characteristics without requiring the expensive high-power beam profiler. This copying approach enables parameter measurement while avoiding the cost and space requirements of the original high-power equipment.
Solution Approach 2:
The patent replaces the expensive, space-consuming high-power beam profiler with a low-power pointer laser system combined with an imaging sensor. This substitution uses much cheaper components that can be easily integrated into the laser processing machine, eliminating the need for separate calibration equipment while maintaining measurement capability.
2Measurement precision
If a high-power beam profiler is used for calibration, then calibration accuracy is improved, but ease of operation deteriorates due to setup complexity
Solution Approach 1:
The patent merges the calibration function into the existing laser processing machine by integrating the pointer laser and imaging sensor within the machine structure. The pointer laser is combined with the processing laser path, and the imaging sensor is positioned to capture beam characteristics during normal operation. This integration eliminates the need for separate calibration equipment and simplifies the calibration process to be performed during routine machine operation.
Solution Approach 2:
The system enables self-calibration by using the machine's own pointer laser and imaging sensor to automatically measure and adjust laser head parameters. The controller processes images from the imaging sensor and automatically adjusts optical components to optimize beam quality, eliminating the need for manual calibration procedures and external equipment.
3Reliability
If routine calibration is performed with high-power equipment, then parameter monitoring reliability is improved, but productivity decreases due to equipment unavailability
Solution Approach 1:
The patent implements periodic calibration using the integrated low-power pointer laser and imaging sensor system. The controller automatically performs calibration measurements at predetermined intervals or when triggered by specific conditions, allowing routine monitoring of laser head parameters without requiring continuous use of high-power equipment. This periodic action maintains reliability while minimizing impact on productivity.
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 cost-effective and efficient calibration of laser processing machines by compensating for mechanical tolerances and environmental factors, ensuring precise operation without the need for high-power equipment.
Implementation Method 1
The imaging sensor is configured to image an optical beam of the laser source from the laser head
Data Source
AI summary
An apparatus calibrates a laser processing machine and includes an imaging sensor and a controller. The controller directs output of a beam from the machine's low power pointer laser and directs an actuator at measurement conditions. Images of the beam are obtained by an imaging sensor, and the controller measures a parameter of at least one of the machine's optical components. The controller then outputs an indication of the machine indicative of the measured parameter. For example, the controller can calculate a focus position of the beam from the laser head so the Z-position of the laser head can be adjusted for any discrepancies. In other examples, the controller can determine an offset of the fiber tip of the head so adjustments to operations can be made, or the controller can determine centering of the beam in the head's nozzle so adjustments can be made.