Optical Height Measurement for CNC Laser Focus and Material Mapping
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Solution Overview
Problem
Computer numerically controlled (CNC) machines face challenges in accurately processing materials due to inconsistencies in material height and thickness, leading to suboptimal design placement and increased scrap material, particularly in decentralized manufacturing settings where skilled professionals are scarce.
Innovation Solution
The implementation of a system that includes an optical assembly with emitters and detectors to measure light intensity and determine material type and distance, enabling precise laser beam focusing and edge detection, combined with multipoint distortion correction techniques to generate accurate height maps and improve visualization and motion planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing techniques are used without height measurement, then device complexity is reduced, but manufacturing precision deteriorates due to inconsistencies in material height and thickness
Solution Approach 1:
The system performs height measurements and material characterization before the actual processing operation. The optical assembly with emitters and detectors measures material properties in advance, allowing the CNC machine to pre-calculate compensation values and adjust processing parameters beforehand, eliminating the need for complex real-time adjustment mechanisms during processing
Solution Approach 2:
The patent replaces complex mechanical measurement systems with an optical measurement system. Instead of using mechanical probes or contact-based height gauges, the system uses optical emitters and detectors to non-contactively measure material height and thickness, significantly reducing mechanical complexity while improving measurement speed and precision
2Manufacturing precision
If skilled professionals are used to manually adjust processing parameters, then manufacturing precision improves, but loss of time increases due to the scarcity and time-consuming nature of manual intervention
Solution Approach 1:
The system performs self-characterization and self-adjustment without requiring skilled operators. The optical assembly automatically measures material properties, the controller automatically calculates compensation parameters, and the system automatically adjusts processing parameters, enabling decentralized manufacturing without skilled professionals while maintaining high precision
Solution Approach 2:
The system implements automated feedback loops where height measurement data is continuously fed back to the controller, which automatically adjusts processing parameters based on the measured material variations. This closed-loop control system replaces manual expert judgment with automated decision-making, eliminating setup time while maintaining precision
3Loss of substance
If material height inconsistencies are not measured, then device complexity is reduced, but loss of substance increases due to increased scrap material
Solution Approach 1:
The system measures material height and thickness variations before processing begins, allowing pre-calculation of compensation parameters. This preliminary measurement enables the system to optimize material usage and minimize scrap by adjusting design placement and processing parameters in advance, rather than discovering issues during or after processing
Solution Approach 2:
The system dynamically changes processing parameters based on measured material properties. By detecting actual material height and thickness, the controller adjusts laser power, speed, and focal position to maintain consistent processing quality across varying material conditions, preventing defects that would otherwise become scrap material
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 enhances the accuracy of material processing, minimizes scrap material, and improves user experience by allowing for precise design placement and efficient use of materials, even in decentralized manufacturing environments without requiring skilled professionals.
Implementation Method 1
one or more detectors are configured to measure an intensity of light emitted from the one or more emitters and reflected off the surface of the material
Data Source
AI summary
Disclosed embodiments include a head attached to a gantry. The head includes an optical assembly to focus a laser beam onto a surface of a material to be processed by a CNC machine and a measurement assembly with emitter(s) and detector(s), where the detector(s) are for measuring intensity of light emitted from the emitter(s) and reflected off the surface of the material. Processors are configured to (i) determine a material type of the material, (ii) determine a distance between the optical assembly and the material surface based on (a) measurement(s) of the intensity of the light emitted from the emitter(s) and reflected off the material surface, and (b) measurement parameter(s) associated with the determined material type, and (iii) control focusing of the laser beam onto the surface of the material based on the determined distance between the optical assembly and the surface of the material.