Laser Processing Quality Inspection Using Secondary Emission Imaging
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Solution Overview
Problem
Current methods for verifying compliance and quality inspection in laser material processing lack comprehensive capture of variables such as optical component degradation, alignment, and environmental effects, relying heavily on data-centric approaches that require technical expertise and do not directly relate to the quality of the processed part.
Innovation Solution
A method and system that utilize a sensor to generate raw image data of secondary emissions during laser material processing, analyze this data to determine the quality of the process, and apply image enhancement techniques to verify compliance with specifications, including geometry, coverage, and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a data-centric approach is used to record laser equipment process parameters, then a digital record of processing is obtained, but the record does not directly relate to the quality of the part and requires technical expertise for analysis
Solution Approach 1:
The patent captures optical emissions (light) generated during laser processing as a visual copy/image of the process. This image directly represents the quality characteristics of the processed area, eliminating the need for expert interpretation of numerical parameters. The optical emission image serves as a direct visual record that can be automatically analyzed by image processing algorithms to determine compliance with specifications.
2Loss of information
If only laser parameters are recorded, then a portion of important variables are captured, but other factors such as optical component degradation, optical alignment, surface condition and environmental effects are not captured
Solution Approach 1:
The patent introduces an optical emission capture system as an intermediary that indirectly measures multiple process variables simultaneously. Instead of directly monitoring optical component degradation, alignment, surface condition, and environmental effects with separate sensors, the system captures the optical emissions generated during processing, which contain information about all these factors. This single measurement approach captures comprehensive process information without requiring a complex array of direct measurement devices.
3Measurement precision
If technical expertise is required to analyze process data, then detailed analysis is possible, but the process becomes inaccessible to non-experts and reduces productivity
Solution Approach 1:
The patent replaces the manual expert analysis process with an automated image processing system. Computer vision algorithms and machine learning models automatically analyze the optical emission images to determine quality metrics and compliance status. This substitution eliminates the need for human experts to manually interpret data, enabling rapid automated quality verification while maintaining or improving analysis precision through consistent algorithmic evaluation.
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 approach provides a direct and non-expertise-requiring means to assess the quality of laser material processing, ensuring compliance with specifications and enabling real-time rejection or reworking of substandard workpieces, thereby improving the reliability and efficiency of the manufacturing process.
Implementation Method 1
performing laser material processing on a workpiece
Implementation Method 2
generating, by a sensor, raw image data of secondary emissions during the laser material processing
Data Source
AI summary
A method for quality inspection of laser material processing includes performing laser material processing on a workpiece and generating, by a sensor, raw image data of secondary emissions during the laser material processing of the workpiece. The method also includes determining a quality of the laser material processing by analyzing the raw image data of the secondary emissions.