Laser Nozzle Alignment Sensor Using Camera and Pilot Laser
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Solution Overview
Problem
Existing methods for determining the alignment of a laser beam relative to a gas nozzle in laser cutting machines are not portable, require fixed measuring positions, and pose safety hazards due to the use of the actual laser beam, making them inefficient and costly for use across multiple machines.
Innovation Solution
A portable sensor device with a camera and pilot laser system that allows for simultaneous visualization of the nozzle orifice and pilot laser, using internal illumination and optical filters to adjust the laser beam alignment without the need for the actual cutting laser, equipped with a wireless interface for easy operation across various machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the actual laser beam is used for alignment determination, then the alignment accuracy is improved, but safety hazards increase
Solution Approach 1:
The patent introduces a pilot laser as an intermediary device that generates a visible laser beam for alignment determination without using the actual high-power cutting laser beam. The pilot laser serves as a safe mediator that allows operators to visualize and adjust the beam path while eliminating the safety hazards associated with using the real cutting laser for alignment purposes.
Solution Approach 2:
The patent creates a copy of the laser beam path using the pilot laser, which replicates the beam trajectory and allows alignment determination without requiring the actual cutting laser beam. This optical copy enables safe visualization and adjustment while maintaining alignment accuracy.
2Measurement precision
If a fixed measuring station is used for alignment determination, then measurement capability is improved, but portability and versatility deteriorate
Solution Approach 1:
The patent transforms the alignment measurement system from a fixed, stationary measuring station into a dynamic, portable device that can be easily moved and adapted to different laser cutting machines. The sensor housing with integrated camera and pilot laser can be positioned at various locations and attached to different machines, providing both measurement capability and versatility.
Solution Approach 2:
The patent designs the alignment determination device as a universal tool that can be used across multiple laser cutting machines. The sensor housing with integrated camera device and pilot laser system can be attached to different machines and performs multiple functions including beam visualization, alignment measurement, and adjustment verification, eliminating the need for dedicated fixed measuring stations for each machine.
3Measurement precision
If the actual laser beam is used for alignment, then alignment determination is possible, but the process time increases due to iterative adjustments
Solution Approach 1:
The patent enables preliminary alignment adjustments by using the visible pilot laser beam to pre-position and pre-align the optical components before activating the actual cutting laser beam. Operators can perform initial alignment, focus adjustment, and beam path optimization using only the pilot laser and camera visualization, reducing the need for iterative adjustments with the real laser and thereby reducing total process time.
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 safe, efficient, and cost-effective alignment of laser beams across multiple machines, reducing the risk of health hazards and improving cutting performance by allowing for precise adjustment of the laser beam without the need for fixed positions or specialized tools.
Implementation Method 1
a camera device (16) comprising a camera (18), where the camera device (16) is provided in the sensor housing (14) so that the camera (18) faces a tip (20) of the gas or cutting nozzle (22) when the sensor device (10) is mounted to the laser machining head (11) for visualizing an orifice (23) of the gas or cutting nozzle (22) and a pilot laser (24) simultaneously
Data Source
Figure 1~2
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AI summary
The present invention relates to a sensor device for determining alignment/misalignment of a laser beam relative to a gas nozzle of a laser machining head which comprises a sensor housing provided with mounting means adapted to mount the housing to a laser machining head, a camera device comprising a camera, the camera device is provided in the sensor housing, so that the camera faces the tip of the gas nozzle when the sensor housing is mounted to the laser machining head for visualizing an orifice of the gas nozzle and a pilot laser simultaneously, and output means for outputting image signals obtained by the camera.