Laser Processing Sensor Calibration Using a Reference Beam Path
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Solution Overview
Problem
The photoelectric conversion characteristic of optical sensors in laser processing devices changes over time and is influenced by environmental conditions, leading to inaccurate monitoring and quality determination of laser processing, as existing calibration methods fail to correctly correct for these changes and variations.
Innovation Solution
A laser processing device with a built-in reference beam source and optical measuring instrument for calibrating the optical sensor, allowing for timely correction of electrical-to-optical conversion characteristics and photoelectric conversion characteristics, improving calibration accuracy and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional calibration methods using laser oscillation unit and workpiece sample are used, then calibration can be performed, but the photoelectric conversion characteristic of the optical sensor cannot be corrected accurately due to additional variations from optical system and test beam intensity changes
Solution Approach 1:
The patent extracts the calibration function from the complex laser processing system by introducing a dedicated calibration light source that emits light through a dedicated calibration optical path directly to the optical sensor, separating it from the laser oscillation unit, workpiece sample, and processing optical path. This isolation eliminates confounding variables and enables accurate measurement of photoelectric conversion characteristics.
Solution Approach 2:
The patent introduces a calibration light source as an intermediary element that provides a stable, controllable light beam for calibration purposes. This intermediary allows direct measurement of the optical sensor's photoelectric conversion characteristics without involving the laser oscillation unit, optical path variations, or workpiece sample, thereby enabling precise correction of sensor drift.
2Ease of operation
If existing calibration procedures are used, then calibration can be performed, but the process becomes troublesome and large-scale due to involvement of laser oscillation unit and workpiece sample
Solution Approach 1:
The patent extracts the calibration function from the complex laser processing system by introducing a dedicated calibration light source that emits light through a dedicated calibration optical path directly to the optical sensor, separating it from the laser oscillation unit, workpiece sample, and processing optical path. This isolation eliminates confounding variables and enables accurate measurement of photoelectric conversion characteristics.
Solution Approach 2:
The calibration system is designed to be self-contained with the calibration light source, calibration optical path, and optical sensor all integrated within the processing head. This allows the optical sensor to be calibrated in situ without requiring external equipment or complex setup procedures, making the calibration process simple and routine.
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 configuration enhances the accuracy, reproducibility, and workability of optical sensor calibration, leading to improved monitoring performance and consistent quality determination of laser processing.
Implementation Method 1
A beam to be measured which is generated or reflected near a processing point of the workpiece is received by the optical sensor through an optical system in the processing head. The laser processing device performs a predetermined signal process for an electric signal (sensor output signal) obtained by photoelectric conversion of the optical sensor
Implementation Method 2
a radiation source 100 that generates light L that passes through a calibration optical path to an optical sensor 50
Data Source
Figure 1
Figure 2~3
Figure 4~4(b)
AI summary
The present laser processing device has a laser oscillator (10), a laser power supply (12), a control unit (14), an optical fiber cable (16), an electric cable (18), a processing head (20), an operation panel (22) and a laser processing monitor unit (24). The laser processing monitor unit (24) includes the control unit (14), the operation panel (22), a sensor signal processing unit (26) and a sensor unit (30) as a basic configuration for a main function, that is, a monitoring function, and additionally includes a reference beam source (100), a reference beam source power supply (102), an optical measuring instrument (104) and an optical path switching unit (105) as a calibration unit (32) for calibrating an optical sensor (50) incorporated in the sensor unit (30).