Laser Processing System Defect Detection
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Solution Overview
Problem
Conventional laser processing systems face challenges in accurately processing three-dimensional workpieces due to difficulties in specifying and executing processing patterns in three dimensions, leading to unprintable or defective areas, and lack means for detecting and preventing printing defects, resulting in wasted materials and increased user effort.
Innovation Solution
A laser processing system with a method and computer program for setting processing conditions that includes a three-dimensional profile of the workpiece and processing pattern, featuring a defective area detection device to identify unprocessable areas and provide warnings, allowing for precise control and prevention of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three-dimensional laser processing is performed on complex workpieces, then the processing capability is improved, but the occurrence of unprintable and defective areas increases
Solution Approach 1:
The system performs preliminary detection of unprintable and defective areas before actual laser processing by calculating the three-dimensional profile of the workpiece and simulating laser beam incidence angles. This advance detection allows users to adjust processing patterns or workpiece positioning to avoid defective areas, thereby maintaining high processing quality while preserving three-dimensional processing capability.
Solution Approach 2:
The system provides feedback by displaying detected unprintable and defective areas on a screen to guide users in adjusting processing parameters or workpiece positioning. This feedback mechanism enables users to optimize processing patterns to avoid defective areas, resolving the contradiction between maintaining three-dimensional processing versatility and ensuring processing quality.
2Adaptability or versatility
If conventional laser processing systems process three-dimensional works, then the processing scope is expanded, but the user effort and time required increases
Solution Approach 1:
The system performs automatic detection of unprintable and defective areas by computationally analyzing the three-dimensional workpiece profile and laser beam geometry, eliminating the need for manual trial-and-error processing. This automation significantly reduces user effort and time while maintaining expanded three-dimensional processing scope.
Solution Approach 2:
The system performs preliminary calculation and detection of problematic areas before actual processing begins, allowing users to make informed adjustments in advance rather than spending time correcting defects during or after processing. This preliminary analysis大幅 reduces the time and effort required for three-dimensional work processing.
3Ease of operation
If processing patterns are specified without defect detection, then the operation simplicity is maintained, but the material waste increases
Solution Approach 1:
The system performs automatic detection of defective areas before processing begins, allowing users to adjust patterns to avoid waste without adding complex manual inspection steps. This preliminary automated detection prevents material waste while maintaining ease of operation.
Solution Approach 2:
The system provides visual feedback showing defective areas that would result from current processing patterns, enabling users to make informed adjustments to avoid material waste. This feedback mechanism prevents waste while keeping the operation simple and intuitive.
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 accurate processing by ensuring that the processing pattern falls within a processable area, reducing defects and user effort by providing real-time warnings and highlighting unprocessable areas, thereby improving the efficiency and quality of laser processing.
Implementation Method 1
Excitation light generated by a laser excitation device 6 of the laser control unit 1 excites a laser media 8 of a laser oscillator 50 of the laser output unit 2. A laser beam L emanating from the laser media 8
Implementation Method 2
A laser beam L emanating from the laser media 8 is expanded in beam diameter by a beam expander 53 and directed toward a scanning head 9
Implementation Method 3
The scanning head 9 deflects the laser beam L so as to scan a work W in a given scan field. The scanning device 9 comprises a pair of galvanic mirrors that form an X-axis scanner 14a and a Y-axis scanner 14b
Implementation Method 4
The scanning device 9 is provided with focusing means such as an fθ lens system for focusing the laser beam in a given scan field
Implementation Method 5
The scanning device 14 comprises a Z-axis scanner comprising a lens system capable of varying its focal length which is referred to as a working distance to a given scan field
Data Source
AI summary
A method of setting processing data for a computer-assisted laser processing apparatus is disclosed, along with a system for setting a laser processing data. The method comprises a function of setting a profile of a three-dimensional object and a processing pattern, a function of generating processing data representing the processing condition, a function of visually displaying representation of the processing data on a display and a function of detecting an defective area of the object surface that is processable but defectively with the laser beam under the printing conditions by making a calculation based on the object profile and an incident angle of the laser beam incident upon the object surface and hiding a processing pattern from the display means when the processing pattern cuts across the defective area.