Laser Microjet Camera Alignment for Small 3D CMC Features
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Solution Overview
Problem
Machining ceramic matrix composites (CMCs) is challenging due to their hardness and brittleness, and existing alignment methods for waterjet guided laser technology face difficulties with small features and nonplanar surfaces.
Innovation Solution
A waterjet guided laser device with a camera system comprising multiple cameras around the nozzle generates a composite image to precisely align the nozzle with the workpiece, enabling accurate material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a retractable touch probe or off-set camera is used for alignment, then the waterjet guided laser device can locate the waterjet nozzle to the part, but alignment becomes difficult due to physical interference between parts with nonplanar surfaces and the nozzle head assembly
Solution Approach 1:
The patent replaces the mechanical touch probe system with an optical camera system for alignment. The camera system captures images of the workpiece and nozzle, allowing alignment to be performed visually without physical contact. This eliminates the physical interference problem between the mechanical probe and nonplanar surfaces while maintaining or improving alignment precision.
Solution Approach 2:
The patent transitions from a single-point mechanical contact measurement (touch probe) to a multi-dimensional visual field approach (camera system). By capturing images from multiple angles and processing them into a composite view, the system achieves alignment in three-dimensional space without physical contact, resolving the interference issue with nonplanar surfaces.
2Ease of operation
If traditional alignment methods are used, then the system structure remains simple, but alignment via touch probe and camera is difficult due to physical interference with small holes and nonplanar surfaces
Solution Approach 1:
The camera system serves multiple functions: it captures images for alignment, provides visual feedback during operation, and can inspect the workpiece. This multi-functionality improves ease of operation across different tasks while the modular design keeps the overall system complexity manageable.
3Adaptability or versatility
If waterjet guided laser technology is used to machine CMCs, then complex 3D holes can be produced, but alignment precision is reduced due to physical interference with the nozzle head assembly
Solution Approach 1:
The patent replaces the mechanical alignment system with an optical vision system that can accurately locate and align with complex 3D features without physical contact. This allows the waterjet guided laser to maintain high manufacturing precision when machining complex 3D holes in CMCs, eliminating the alignment errors caused by physical interference between the mechanical probe and the complex geometry.
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 camera system enhances alignment precision, particularly for small features and nonplanar surfaces, improving the efficiency of machining CMCs.
Implementation Method 1
capturing a plurality of images of the workpiece with a corresponding plurality of cameras
Implementation Method 2
ejecting a waterjet from an aperture of the nozzle, and impinging the waterjet against the workpiece causing a corresponding removal of material therefrom
Implementation Method 3
transmitting a laser through a high-pressure water column to the surface of the part
Data Source
AI summary
A device for forming a feature in a workpiece includes a waterjet guided laser device translatable relative to the workpiece. The waterjet guided laser device includes a head assembly having a nozzle comprising an aperture for ejecting a waterjet with an internal laser beam, and a camera system comprising a plurality of cameras disposed about the nozzle.