Laser Processing Head Nozzle Centering via Sapphire Beam Conversion
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Solution Overview
Problem
Existing laser processing machines face challenges in repeatedly centering the laser beam within the nozzle bore of the laser processing head due to thermal instabilities and contamination of focusing lenses, requiring complex optical measures and multiple sensors, which complicates the centering process and can lead to measurement distortions.
Innovation Solution
A novel nozzle construction with a beam handling unit, such as a sapphire ring, that converts the primary CO2 laser beam into secondary heat radiation, allowing for detection by sensors in the near-infrared or visible range, enabling automated and precise centering without external temperature sensors or complex optical setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mirror surface or combined scattering/mirror surface with radial curvature is used to draw off laser radiation, then the laser beam position can be detected, but the device complexity increases and measurement precision deteriorates due to contamination and distortion
Solution Approach 1:
The patent extracts the beam position detection function from the complex optical system (mirrors, scattering surfaces) and implements it through a simpler sensor-based system that directly detects the laser beam position without requiring complex optical components to redirect or modify the beam
Solution Approach 2:
The patent introduces an intermediary sensor system that mediates between the laser beam and the detection system, allowing direct measurement of beam position without requiring the laser beam to interact with complex optical surfaces that could be contaminated or distorted
2Measurement precision
If multiple sensors are used to detect laser radiation intensity at different measuring surfaces, then beam position can be determined, but the device complexity and risk of measurement distortion increase
Solution Approach 1:
The patent extracts the essential measurement function from a multi-sensor system and implements it through a single sensor that directly detects beam position, eliminating the need for multiple sensors and complex intensity comparison algorithms
Solution Approach 2:
Instead of using multiple sensors to detect intensity variations and calculating position from these variations, the patent inverts the approach by using a single sensor to directly detect the beam position through a different physical mechanism, simplifying the measurement system
3Extent of automation
If the laser beam is moved relatively to the nozzle opening along the propagation direction to achieve centering, then automated centering is possible, but thermal loading and wear on the nozzle increase
Solution Approach 1:
The patent performs preliminary detection of the laser beam position before any relative movement occurs, allowing the system to plan and execute minimal necessary movements to achieve centering, thereby reducing thermal loading and wear on the nozzle
Solution Approach 2:
The patent implements a feedback mechanism where the sensor continuously monitors beam position during the centering process, allowing real-time adjustments that minimize unnecessary movement and reduce thermal loading on the nozzle while maintaining automated control
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 solution allows for repeatable and precise automated centering of the laser beam, reducing the need for special optical measures and minimizing wear on the nozzle and beam handling unit, even at high laser power, thereby ensuring high-quality laser cutting with reduced thermal loading.
Implementation Method 1
a beam handling unit, such as a sapphire ring, that converts the primary CO2 laser beam into secondary heat radiation
Data Source
AI summary
Laser processing machines and methods for adjusting focused laser beams. Laser processing heads have nozzle with openings admitting primary laser beam. An orientation device is included, as well as at least one sensor to mutually center primary beam and opening of nozzle. A first beam handling unit is arranged near the nozzle opening and may convert primary beam into a secondary wide-band heat beam, and then may emit this secondary beam towards a sensor; or may reflect/scatter at least a portion of the primary beam towards sensor. The sensor detecting the converted secondary beam is arranged within the laser processing head. In an adjustment process, a primary beam may be converted into a wide-band heat radiation as secondary radiation at the beam handling unit, and emitted and/or diverted into a scattered/reflex beam towards the sensor. Respective position of nozzle opening center and primary beam is calculated from sensor-measured values, and nozzle center and beam center are automatically displaced to mutual center. The axial position of beam focus may be also be measured and set via the nozzle centering procedure.