Laser Processing Head Distance Measurement via Beam Splitting
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Solution Overview
Problem
Existing laser processing technologies face challenges in accurately measuring the distance between a work and a processing head, particularly in remote laser welding, and lack real-time quality checking capabilities, leading to inefficiencies and increased costs due to the need for separate light sources and measuring instruments.
Innovation Solution
A laser processing device and system that utilize optical path splitting means to split the processing laser beam, allowing for simultaneous measurement of distance and quality evaluation by comparing the intensity and time of detection signals from incident and reflected beams using a single light source, eliminating the need for additional measurement tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate laser for measurement is installed inside the processing head, then distance measurement capability is achieved, but cost increases and space requirements increase
Solution Approach 1:
The processing laser beam is used for multiple purposes: both for laser processing and for distance measurement. The same laser light serves dual functions, eliminating the need for a separate measurement laser and reducing both cost and space requirements while maintaining measurement capability
Solution Approach 2:
The measurement function is merged with the processing function by using the processing laser beam itself for distance measurement. The optical path splitting means divides the processing beam to enable simultaneous processing and measurement operations with a single laser source
2Measurement precision
If a measuring instrument is installed outside the processing head, then measurement capability is achieved, but the system complexity increases and accurate distance measurement becomes difficult
Solution Approach 1:
The measurement function is integrated into the processing head by using the processing laser beam itself. The optical path splitting means is installed within the processing head to divide the beam, enabling measurement without external instruments and reducing system complexity while maintaining measurement accuracy
Solution Approach 2:
The optical path splitting means acts as an intermediary element that divides the processing laser beam into separate paths: one for processing and one for measurement. This mediator enables both functions to coexist using a single laser source without requiring external measurement instruments
3Measurement precision
If robot position measurement is used to determine distance, then measurement capability is achieved, but absolute position accuracy and repeatability are insufficient
Solution Approach 1:
The mechanical robot position measurement system is replaced with an optical measurement method using the processing laser beam itself. By measuring the time of flight of the laser light, the system achieves higher accuracy and repeatability independent of robot positioning errors
Solution Approach 2:
The processing laser beam serves as an intermediary carrier for distance measurement information. By modulating the laser and measuring its round-trip time, the system obtains accurate distance data without relying on robot position sensors, thereby improving measurement reliability
4Measurement precision
If separate measurement instruments and light sources are used, then distance measurement is achieved, but processing efficiency decreases due to lack of real-time quality checking
Solution Approach 1:
The processing laser beam continuously serves both processing and measurement functions simultaneously. The optical path splitting enables parallel operation of processing and quality checking without interruption, maintaining continuous productive action while providing real-time feedback
Solution Approach 2:
The system provides real-time feedback by continuously monitoring the reflected beam during processing. This feedback enables immediate quality assessment and distance adjustment, improving processing efficiency through closed-loop control without requiring separate measurement cycles
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 and cost-effective measurement of distance and real-time quality assessment during processing, improving processing efficiency and reducing the need for separate measurement equipment.
Implementation Method 1
a photodetector that detects the intensity of the processing laser beam split by the optical path splitting means, and outputs a detection signal having a signal intensity responsive to the detected intensity
Implementation Method 2
The detection time comparing unit measures a distance between the laser processing device and the work by comparing a time of detection of an intensity received from the photodetector responsive to the incident beam and a time of detection of an intensity received from the photodetector responsive to the reflected beam
Implementation Method 3
at least one optical path splitting means that splits the processing laser beam
Implementation Method 4
optical path splitting means that splits the processing laser beam
Data Source
AI summary
An object is to provide a laser processing device and a laser processing system capable of measuring a distance between a work and a processing head accurately and simply and capable of checking the quality of processing in real time during the processing. Provided are: a photodetector that detects the intensity of a processing laser beam split by optical path splitting means, and outputs a detection signal having a signal intensity responsive to the detected intensity together with a time of detection of the intensity; a signal intensity comparing unit that compares the signal intensities of multiple detection signals received from the photodetector; and a detection time comparing unit that compares times of detection of multiple intensities. The signal intensity comparing unit measures a processing quality by comparing the signal intensity of a detection signal received from the photodetector responsive to an incident beam on a work and the signal intensity of a detection signal received from the photodetector responsive to a reflected beam from the work. The detection time comparing unit measures a distance between a laser processing device and the work by comparing times of detection of the intensities.