Scanner Head Beam Position Sensor for Offline Laser Adjustment
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Solution Overview
Problem
Existing scanner heads for laser material processing require complex, expensive, and time-consuming adjustments to control the angle of incidence and position of the laser beam, which often necessitate influencing components upstream of the scanner head, limiting precision and speed.
Innovation Solution
A scanner head with a beam position system comprising at least two controllable movable optical elements and a beam position sensor that allows for offline adjustment of the laser beam's position and angle of incidence, enabling independent control of four geometric parameters, including x-y coordinates and direction of propagation, without affecting components upstream of the scanner head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If adjustment is performed through components upstream of the mirror assembly, then beam position can be monitored, but the adjustment process becomes highly complex, protracted, and expensive
Solution Approach 1:
A beam splitter is introduced as an intermediary component that separates the monitoring function from the adjustment components. The beam splitter directs a portion of the laser beam to sensor elements while allowing the main beam to proceed to the mirror assembly, enabling independent monitoring without complicating the adjustment mechanism
Solution Approach 2:
The system is divided into independent functional modules: the mirror assembly for beam steering, the beam splitter for beam separation, and sensor elements for monitoring. This segmentation allows each component to perform its specific function without interfering with others, simplifying the overall adjustment process
2Manufacturing precision
If adjustment is performed through components upstream of the scanner head, then beam parameters can be controlled, but the process becomes time-consuming and affects external components
Solution Approach 1:
The scanner head is equipped with integrated sensor elements and a beam splitter that enable it to autonomously monitor and adjust its own beam parameters. This self-service capability eliminates the need for external adjustment equipment and reduces adjustment time by performing calibration directly at the source
Solution Approach 2:
The sensor elements continuously monitor beam parameters in advance, allowing the system to detect deviations and perform corrections before they affect the final beam output. This preliminary detection and correction mechanism reduces the need for time-consuming post-adjustment
3Productivity
If independent adjustment of angle of incidence and path guidance is achieved, then processing speed increases, but system complexity increases
Solution Approach 1:
The beam position system with multiple sensor elements serves multiple functions simultaneously: it monitors beam position, detects angle of incidence, and provides feedback for adjustment. This multi-functionality eliminates the need for separate systems for each parameter, maintaining simplicity while enabling independent adjustment of multiple beam parameters
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 rapid, precise, and cost-effective offline adjustment of the laser beam position and angle of incidence, allowing for high-speed processing without influencing external components, thus improving processing efficiency and reducing manufacturing costs.
Implementation Method 1
a beam position sensor (4) for detecting an actual position of the laser beam (9), wherein the beam position sensor (4) is formed in such a manner that, by means of it, at least four independent position parameters of the laser beam (9) can be detected
Implementation Method 2
a computing unit (5) for compensating the actual position of the laser beam (9) detected by means of the beam position sensor (4) with a target position (21) and for calculating, from a deviation of the actual position (19) from the target position (21), at least one correction value for the beam position system (3)
Implementation Method 3
a control unit (7) for adjusting the beam position system (3), in particular for adjusting the at least two optical elements, taking into account the at least one correction value
Implementation Method 4
a beam position system (3) for influencing a position of the laser beam (9), wherein the beam position system (3) is upstream of the focusing optics (15) in the direction of propagation of the laser beam (9), wherein the beam position system (3) comprises at least two optical elements, in particular at least two movable optical elements, which can be controlled by means of a control unit (7)
Data Source
AI summary
A scanner head for laser material processing with a laser beam includes focusing optics, and a beam position system that influences a position of the laser beam and is upstream of the focusing optics in a direction of propagation of the laser beam. The beam position system includes at least two controllable movable optical elements by means of which an angle of incidence of the laser beam on a processing surface of a workpiece is adjustable. A processing location of the laser beam on the processing surface is also movable in two dimensions. A beam position sensor is downstream of the beam position system and is configured to detect an actual position of the laser beam or at least four independent position parameters of the laser beam.