Protective Window Fouling Assessment by Weighted Laser-Path Imaging
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Solution Overview
Problem
Existing methods for monitoring the fouling of protective glasses in laser processing machines lack selectivity, leading to unnecessary interruptions or failure to detect detrimental fouling, as they do not differentiate between types of fouling effectively.
Innovation Solution
A method that involves illuminating the transmissive element with a camera to capture an image, analyzing the image to calculate an optical fouling value, weighing pollution based on its distance from the laser beam's path, and using image processing to determine the degree of fouling, allowing for selective detection and triggering cleaning or replacement when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a threshold value is set for scattered light detection, then operation can be maintained, but either operation is unnecessarily interrupted or detrimental fouling is not detected
Solution Approach 1:
The patent applies local quality by differentiating the importance of fouling based on its location. Pollution close to the laser beam path is assigned a higher weight than pollution farther away. This allows the system to tolerate certain levels of fouling in less critical areas while maintaining high sensitivity for fouling in critical areas, thus avoiding unnecessary interruptions while still detecting detrimental fouling.
Solution Approach 2:
The patent changes the parameter of fouling assessment from a simple binary threshold to a weighted quantitative measure. By introducing position-dependent weights and calculating a weighted sum of pollution areas, the system transforms the detection parameter to provide more nuanced information about fouling severity, enabling better decision-making for maintenance scheduling.
2Extent of automation
If visual inspection with sensors is used, then automated detection is achieved, but selectivity in detecting detrimental fouling is lost
Solution Approach 1:
The system maintains automated detection while improving measurement precision by incorporating spatial information into the assessment. Each detected pollution area is weighted based on its distance from the laser beam path, allowing the automated system to differentiate between detrimental and non-detrimental fouling without requiring manual inspection.
Solution Approach 2:
The patent introduces an intermediary calculation layer between the raw sensor data and the maintenance decision. The weighted fouling value calculation acts as a mediator that translates simple scattered light detection into a meaningful assessment of fouling severity, bridging the gap between automated detection and precise fouling evaluation.
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 provides a reliable and selective method for determining the fouling of transmissive elements, ensuring optimal laser power focus and preventing equipment damage by accurately assessing the fouling level and triggering appropriate maintenance actions.
Implementation Method 1
an illumination of the protective glass in combination with sensors (such as photodiodes) that detect scattered light. The higher the fouling, the more scattered light is detected.
Data Source
AI summary
The present disclosure relates to a method of determining a degree of fouling of a transmissive element of a laser processing machine (for example a protective window facing the workpiece). A laser beam is directed through the transmissive element. The method includes illuminating the transmissive element and taking an image, for example by a camera, of the illuminated transmissive element. The image represents pollution of the transmissive element. The image is analyzed for calculating an optical element fouling value that is a quantitative measure of the degree of fouling. In this calculation, the distance of the pollution to an intersection position of the laser beam propagation axis through the transmissive element is taken into account in that the pollution is given a weight by that depends on the distance to the intersection position.