Laser Processing Roughness Estimation With Real-Time Optical Feedback
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Solution Overview
Problem
Current laser processing methods and machines struggle to estimate roughness in real time, leading to inefficiencies and the need for post-processing adjustments, resulting in discarded or reprocessed workpieces.
Innovation Solution
A laser processing method and machine that utilize a monitoring device to acquire images of the processing zone, analyze these images in real time to estimate roughness, and adjust process parameters accordingly to achieve desired roughness levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If roughness is determined in laboratory after laser processing, then measurement precision is improved, but productivity is worsened due to post-processing time and potential rework
Solution Approach 1:
The patent implements real-time roughness estimation during the laser processing operation itself, rather than waiting for post-processing laboratory measurements. The monitoring device captures images of the processing zone throughout the laser operation, and the analysis module continuously estimates roughness parameters, enabling immediate detection and adjustment before the workpiece completes processing.
Solution Approach 2:
The patent replaces the mechanical/laboratory-based roughness measurement system with an optical monitoring and image analysis system. Instead of physically extracting samples for laboratory analysis, the system uses optical sensors to capture images of the processing zone and algorithms to estimate roughness from these images, enabling real-time feedback during processing.
2Manufacturing precision
If process parameters are updated after roughness determination, then manufacturing precision is improved, but loss of time increases due to reprocessing or discarding workpieces
Solution Approach 1:
The patent implements a closed-loop feedback system where the analysis module continuously monitors the processing zone and estimates roughness in real-time. When the estimated roughness deviates from desired values, the control unit automatically adjusts process parameters (such as laser power, scanning speed, or focal position) to correct the deviation, ensuring the workpiece meets specifications without requiring post-processing intervention.
3Productivity
If real-time monitoring is implemented, then productivity is improved by reducing rework, but device complexity increases due to additional monitoring and control systems
Solution Approach 1:
The monitoring device is designed to perform multiple functions: it captures images of the processing zone for real-time roughness estimation, provides visual documentation of the processing operation, and supplies data for process optimization. This multi-functionality reduces the need for separate dedicated monitoring systems while achieving real-time quality control.
Data Source
AI summary
A laser processing method may comprise: a) directing a laser beam onto the work piece at a processing zone of the work piece for executing a laser processing; b) executing a relative movement between the laser beam and the work piece; c) acquiring optical signals, more preferentially a plurality of acquired images, from the processing zone; d) determining a time course of one or more characteristic parameters obtained starting from the optical signals, more preferentially from the plurality of acquired images; e) estimating in dependence of each time course of the one or more characteristic parameters a roughness obtained during the laser processing. During the step e) at least one respective statistical parameter is determined from the time course of the one or more characteristic parameters and afterwards a continuous estimate in real time of the roughness is calculated in function of each determined statistical parameter.