Dual-Optics Laser Seam Tracking for Direction-Independent Machining
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Solution Overview
Problem
Existing laser processing systems, such as those used for welding and cutting, face challenges in precisely tracking seams regardless of processing direction due to fixed alignment methods, limiting their applicability and accuracy.
Innovation Solution
A laser processing system incorporating a first deflection optics for two-dimensional movement of the processing laser beam and a second deflection optics for independent movement of a measuring beam, coupled via a beam splitter, allows for direction-independent seam tracking using optical coherence tomography, enabling precise positioning of the laser beam along the seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If light section methods with fixed alignment are used to determine seam position, then the measurement process is simple, but the method only works for a fixed welding direction and is not direction-independent
Solution Approach 1:
The patent divides the measurement system into separate functional modules: a laser line generator for projecting measurement lines, a camera for capturing images, and a control unit for processing. This segmentation allows the measurement functionality to be independently configured and adapted to different welding directions without redesigning the entire system, achieving direction-independence while maintaining manageable complexity
Solution Approach 2:
The measurement system is designed to perform multiple functions: it can determine seam positions for welding directions from any angle, not just a fixed direction. The laser line projection and camera capture mechanism works universally for different orientations, making the system adaptable to various welding configurations without requiring direction-specific adjustments
2Adaptability or versatility
If the entire optics are rotated to follow the course of the seam, then direction-independent measurement becomes possible, but this is only possible to a limited extent even with robot-guided processes
Solution Approach 1:
The patent extracts the measurement functionality from the processing optics and implements it as a separate, stationary measurement system. Instead of rotating the entire optics assembly, the measurement device remains fixed while independently determining seam positions for any welding direction, significantly simplifying operation and removing mechanical rotation requirements
Solution Approach 2:
The patent introduces a control unit as an intermediary that processes images captured by the camera and calculates seam positions mathematically. This mediator enables direction-independent measurement through computational methods rather than physical optics rotation, making the system easier to operate and more flexible
3Measurement precision
If traditional light section methods are used, then the alignment is fixed, but this limits the applicability to specific welding directions
Solution Approach 1:
The patent implements a dynamic measurement system where the camera captures images and the control unit dynamically calculates seam positions based on the actual welding direction. Instead of fixed alignment, the system adapts its measurement and calculation process to match any welding direction, maintaining precision while providing full directional flexibility
Solution Approach 2:
The system changes the measurement parameters dynamically based on welding direction. The control unit adjusts the analysis of captured images according to the specific welding configuration, allowing precise seam position determination for any direction by modifying measurement and calculation parameters rather than physical alignment
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 solution achieves high accuracy in seam tracking and positioning, with a resolution of about 1 μm, significantly improving upon traditional light section methods by allowing direction-independent measurement and precise alignment of the laser beam, enhancing the stability and quality of the welding process.
Implementation Method 1
a coupling device, which is in a beam path of the processing laser beam and is set up to couple the measuring beam into the beam path of the processing laser beam
Implementation Method 2
a first deflection optics, which is set up to deflect a processing laser beam in two spatial directions, a second deflection optics, which is set up to deflect a measuring beam independently of the processing laser beam in two spatial directions
Implementation Method 3
the laser light being supplied via an optical fiber, also referred to as a laser source. The laser light passes through a large number of optical elements, such as lenses, in a device for processing materials using lasers
Data Source
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AI summary
The invention relates to a laser machining system (100), comprising a first deflecting lens system (110), which is designed to deflect a machining laser beam (10) in two spatial directions (x, y), a second deflecting lens system (120), which is designed to deflect a measurement beam (15) in two spatial directions (x, y) independently of the machining laser beam (10), and an incoupling device (130), which is arranged in a beam path of the machining laser beam (10) and is designed to couple the measurement beam (15) into the beam path of the machining laser beam (10).