Laser Machining Head Position Deviation Detection
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Solution Overview
Problem
Current calibration systems for laser machining machines are time-consuming, technically complex, and prone to errors, leading to collisions and incorrectly manufactured components due to unnoticed geometric deviations between the actual and desired positions of the laser machining head.
Innovation Solution
A method involving two machining positions to determine deviations by directing a laser beam onto a workpiece, detecting radiation interaction, and calculating maximum deviations, allowing for quick and effective calibration of the laser machining head's position relative to its desired position, which can be checked at any stage of processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reference component is used for calibration measurements, then position deviations can be detected, but the reference component creates an interfering contour that may lead to collisions and requires time-consuming, complex adjustment
Solution Approach 1:
The patent removes the reference component from the calibration system entirely. Instead of using a separate reference component on the robot base, the invention uses the workpiece itself as the reference, eliminating the interfering contour and collision risks while maintaining position deviation detection capability
Solution Approach 2:
The workpiece serves multiple functions: it is both the object to be processed and the reference for calibration measurements. The through-opening in the workpiece serves dual purposes as both a machining feature and a detection target for position verification
2Measurement precision
If traditional calibration methods are used, then position accuracy can be verified, but the process is time-consuming and complex
Solution Approach 1:
The calibration verification is integrated into the normal machining process. The through-opening is created during regular workpiece processing, and position verification is performed immediately afterward using the same machining positions, eliminating separate calibration time
Solution Approach 2:
The patent combines the calibration verification process with the normal machining operations. The same laser beam and positioning system used for machining are used for calibration verification, merging two previously separate processes into one
3Device complexity
If human visual inspection is used to detect collision deviations, then simple equipment is needed, but small collision-related deviations cannot be recognized
Solution Approach 1:
The patent introduces an intermediary detection method using radiation detection (camera or radiation detector) to bridge the gap between simple visual inspection and complex measurement systems. The detector captures radiation from the interaction between the laser beam and workpiece material to precisely determine position deviations
Solution Approach 2:
The invention replaces mechanical visual inspection with optical/radiation-based detection. Instead of relying on human eyes to detect physical misalignments, the system uses radiation detection to precisely measure position deviations based on the interaction between laser radiation and workpiece material
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 method simplifies the calibration process, reduces errors, and prevents collisions by enabling rapid detection and correction of geometric deviations, ensuring accurate processing of workpieces without the need for indirect manufacturing precision checks.
Implementation Method 1
detecting radiation which is generated by an interaction between the laser beam and the workpiece
Data Source
AI summary
Implementations of the present disclosure include methods, systems, and computer-readable storage mediums for determining a deviation between an actual position and a desired position of a laser machining head of a laser machining machine. Implementations include actions of selecting at least two different machining positions of the laser machining head, in which a laser beam emitted by the laser machining head is directed onto a desired position of a workpiece, moving the laser machining head into a first selected machining position and forming a through-opening into the workpiece at or around the desired position by operation of the laser beam, moving the laser machining head into a second selected machining position and detecting radiation generated by an interaction between the laser beam and the workpiece, and determining whether there is a deviation between an actual position of the laser machining head and the desired position based on the detected radiation.