Laser Spot Inspection for Optical Path Abnormality Detection
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Solution Overview
Problem
Laser processing apparatuses face issues with optical system distortions due to dirt, flaws, or abnormalities, leading to inaccurate laser beam processing.
Innovation Solution
An inspecting unit that includes a camera to image the laser beam spot and a processing unit to generate three-dimensional light intensity data, determining deviations from expected values to identify optical system issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser processing apparatus operates continuously without inspection, then productivity is maintained, but the optical system develops dirt, flaws, or abnormalities that cause processing inaccuracy
Solution Approach 1:
The inspection unit performs preliminary detection of optical system abnormalities by imaging the laser beam spot and analyzing light intensity distribution before processing errors occur. The determining unit compares measured light intensity against reference values to identify dirt, flaws, or abnormalities in the optical system in advance, allowing maintenance to be scheduled proactively rather than reactively when processing accuracy degrades
Solution Approach 2:
The inspection unit establishes a feedback mechanism that continuously monitors the optical system state by measuring light intensity distribution and comparing it against reference data. When deviations exceed a threshold, the system provides feedback signals to alert operators and trigger maintenance procedures, creating a closed-loop control system that maintains processing accuracy through ongoing monitoring and timely intervention
2Manufacturing precision
If the optical system is inspected frequently, then processing accuracy is maintained, but productivity decreases due to maintenance interruptions
Solution Approach 1:
The inspection unit applies partial inspection by focusing measurement on critical parameters (light intensity distribution at the laser beam spot) rather than comprehensive inspection of the entire optical system. This selective monitoring approach detects abnormalities with high probability while minimizing inspection time and maintaining productivity, performing only the essential measurements needed to ensure processing accuracy
3Manufacturing precision
If the optical system components are cleaned or replaced, then processing accuracy is restored, but device complexity increases due to additional maintenance procedures
Solution Approach 1:
The inspection unit replaces complex manual inspection procedures with automated optical measurement and digital image processing. The camera captures the laser beam spot, the processing unit generates light intensity data and compares it against reference values, and the determining unit automatically identifies abnormalities. This substitution of mechanical/manual inspection with automated electronic measurement simplifies the maintenance workflow while improving detection accuracy and consistency
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
Enables early detection of optical system problems, prompting maintenance to maintain accurate laser processing.
Implementation Method 1
a camera configured to image a spot of the laser beam
Implementation Method 2
a processing unit configured to generate a light intensity at two-dimensional coordinates of an X-coordinate and a Y-coordinate corresponding to a two-dimensional image imaged by the camera
Implementation Method 3
a laser oscillator configured to emit a laser beam and an optical system including a condenser configured to guide and condense the laser beam emitted by the laser oscillator
Data Source
AI summary
An inspecting unit for use in a laser processing apparatus includes a camera configured to image a spot of a laser beam, and a processing unit configured to generate a light intensity at two-dimensional X-Y coordinates corresponding to a two-dimensional image imaged by the camera. The processing unit includes a determining unit configured to generate a three-dimensional approximate curve or an approximate curved surface such that the light intensity corresponding to the two-dimensional coordinates is set as a Z-coordinate, and determine that there is dirt, a flaw, or an abnormality in an optical system on an optical path on the laser oscillator side of a position at which the spot is imaged when a difference between the first light intensity of the Z-coordinate corresponding to the two-dimensional coordinates and a second light intensity indicated by the approximate curve or the approximate curved surface exceeds an allowable value.