Laser Beam Spot Profiling With In-Bed Power Meter Calibration
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Solution Overview
Problem
Current laser cutting systems require tedious and time-consuming calibration to optimize the spot size of a laser beam for cutting substrates, which limits efficiency and flexibility in transferring CNC code between machines.
Innovation Solution
A system and method that automatically measures and correlates the spot size of a laser beam to the laser-head-to-work-bed distance using a power meter and knife-edge plate, allowing the laser cutting machine to determine the necessary distance for a desired spot size, eliminating the need for manual calibration and enabling direct comparability of CNC code between machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration is used to optimize spot size, then measurement precision can be achieved, but productivity is reduced due to time-consuming calibration
Solution Approach 1:
The system performs self-calibration by automatically moving the laser head to predefined positions, measuring spot size using the power meter and knife-edge plate, and storing calibration data without requiring operator intervention. This eliminates manual calibration time while maintaining measurement precision through automated data collection and processing.
Solution Approach 2:
The system performs calibration measurements at multiple predefined positions before actual cutting operations. By pre-establishing the relationship between laser head positions and spot sizes, the system prepares calibration data in advance, eliminating the need for time-consuming manual calibration during production operations.
2Manufacturing precision
If manual calibration is performed for each machine, then spot size optimization is achieved, but adaptability is reduced due to inability to transfer CNC code between machines
Solution Approach 1:
The system creates a digital copy of the calibration data (relationship between laser head positions and spot sizes) that can be stored and transferred between machines. This digital replica allows CNC code developed on one machine to be accurately transferred to another machine with identical spot size characteristics, eliminating the need for recalibration on each machine.
Solution Approach 2:
The calibration system produces universal calibration data that can be applied across multiple laser cutting machines. By establishing a standardized method for measuring and storing spot size versus position relationships, the system enables the same CNC code to operate correctly on different machines, enhancing versatility and interoperability.
3Productivity
If automated measurement system is implemented, then productivity is improved by eliminating manual calibration, but device complexity increases
Solution Approach 1:
The system introduces a power meter and knife-edge plate as intermediary measurement tools between the laser head and the workpiece. These intermediaries automatically capture spot size data at predefined positions, enabling automated calibration without requiring complex image processing or manual measurement techniques, thus balancing automation with manageable system complexity.
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 approach streamlines the calibration process, enhances operational efficiency, and allows for seamless transfer of CNC code between laser cutting machines, ensuring consistent spot size parameters across different setups.
Implementation Method 1
receive power signals from the power meter as the laser beam is translated across the power meter
Implementation Method 2
the knife edge plate forms a blocked portion and a transmission portion defined by a knife edge extending across the power meter
Data Source
AI summary
A laser system includes a controller comprising a processor and a non-transitory machine-readable memory, a laser head configured to output a laser beam, a work bed positioned opposite the laser head, and a power meter communicatively coupled to the electronic control unit and integrated within the work bed. The laser system further includes a knife edge plate positioned between the power meter and the laser head, and a machine-readable instruction set stored in the non-transitory machine readable memory that causes the laser system to perform at least the following when executed by the processor: position the laser head at a distance from the power meter, cause the laser head to output the laser beam, translate the laser head across the power meter, receive power signals from the power meter as the laser beam is translated across the power meter, and calculate a spot size based on the power signals.