Laser Scanner Optical Surface Debris Inspection by Deflected Light
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Solution Overview
Problem
Laser scanners used in aircraft component manufacturing face reduced effectiveness due to debris on their optical surfaces, leading to inferior surface ablation and reduced laser power impact, which affects the quality of the ablation process.
Innovation Solution
An automated inspection system utilizing a directional optical source and an optical detector to detect debris on the laser scanner's optical surface by emitting a light beam that intersects with debris, capturing deflected light, and generating feedback to alert users for cleaning, ensuring the optical surface remains unobstructed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser scanner operates without inspection, then productivity is maintained, but debris accumulates on the optical surface causing reduced laser power and inferior ablation quality
Solution Approach 1:
The inspection system performs preliminary detection of debris on the optical surface before the laser ablation process begins. By using a directional optical source and optical detector to scan the optical surface in advance, the system identifies debris presence beforehand, allowing operators to clean the surface before critical contamination occurs during ablation, thus maintaining high ablation quality without continuous interruptions
Solution Approach 2:
The inspection system establishes a feedback loop where the optical detector continuously monitors the optical surface for debris and provides real-time information to the control system. When debris is detected above a threshold level, the system generates feedback signals to alert operators and pause laser operations, preventing degradation of ablation quality and enabling timely maintenance without significant productivity loss
2Measurement precision
If the laser beam intersects the optical surface, then debris detection is enabled, but the laser power is reduced and ablation effectiveness deteriorates
Solution Approach 1:
The inspection system uses a directional optical source as an intermediary device to detect debris on the optical surface. This separate optical source illuminates the surface at a specific angle, and the optical detector captures scattered light from debris particles. This intermediary detection method allows debris identification without requiring the high-power laser beam to intersect the optical surface, thereby maintaining full laser power for effective ablation while achieving accurate debris detection
Solution Approach 2:
The inspection system creates an optical copy or representation of the optical surface condition by using the directional optical source and detector to map debris locations. The system generates visual or digital representations of debris positions on the optical surface, allowing operators to identify contamination without the laser beam directly interacting with the optical surface, thus preserving laser power while enabling precise debris location identification
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
The system effectively identifies and alerts users to debris on the optical surface, preventing reduced laser power and ensuring high-quality surface ablation by maintaining a clear path for the laser beam, thus enhancing the overall performance of the laser scanner.
Implementation Method 1
The light beam extending across, and just above, the surface of the optical surface will impact on any debris in its path that is on the optical surface and deflect out. The optical detector will capture images of the light
Data Source
AI summary
The present disclosure provides an inspection system and method for inspecting an optical surface of a laser scanner, the system including a directional optical source and an optical detector. The method includes moving one of the laser scanner or the inspection system to a position in which a beam axis of the directional optical source extends across but does not intersect the optical surface, between the optical surface of and the optical detector. The method further includes emitting a light beam from the directional optical source, across the optical surface so that light from the light beam is incident on debris disposed on the optical surface. The method further includes collecting the light at the optical detector to form an image that indicates presence of the debris on the optical surface of the laser scanner; and generating feedback to alert a user of the presence of the debris.