Telecentric Optical Detector Calibration for Multi-Laser Precision
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Solution Overview
Problem
Current laser calibration methods in the laser-processing industry are time-consuming, error-prone, and require significant human intervention, leading to reduced precision and quality due to manual measurement and potential errors.
Innovation Solution
A laser calibration device with a scanning surface, optical detector, and processing unit that generates and detects calibration patterns automatically, allowing for increased automation and accuracy by restricting the optical detector's movement to one or two degrees of freedom and using pattern generation executable instructions to calibrate laser processing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration methods are used with magnifying lenses and human operators, then flexibility and adaptability are maintained, but calibration time increases significantly, measurement precision decreases, and error rates increase
Solution Approach 1:
The patent replaces manual mechanical measurement methods (magnifying lenses, human operators) with an automated optical detection system. The detector automatically captures and processes calibration pattern images, eliminating manual intervention and significantly reducing calibration time while improving measurement precision through consistent, repeatable automated measurements.
Solution Approach 2:
The patent uses digital imaging to create a copy of the calibration pattern on the calibration substrate. The detector captures an optical image of the calibration pattern, which is then processed digitally to determine positions of calibration markings. This copying approach enables rapid, accurate measurement without physical contact or manual manipulation.
2Reliability
If manual calibration processes are employed, then human judgment and adaptability are preserved, but the number of error sources increases and overall reliability decreases
Solution Approach 1:
The patent replaces manual calibration operations with an automated system comprising a detector, processing unit, and control unit. This substitution eliminates human error sources while maintaining systematic control. The automated image capture and processing workflow ensures consistent, reliable results across multiple calibrations.
Solution Approach 2:
The patent implements a feedback mechanism where the detector captures calibration pattern images, the processing unit analyzes these images to determine marking positions, and the control unit uses this information to adjust and optimize laser processing device parameters. This closed-loop feedback system continuously improves calibration reliability.
3Productivity
If automated optical detection is implemented with restricted degrees of freedom, then calibration speed and productivity increase, but measurement precision may be compromised without telecentric optics
Solution Approach 1:
The patent employs a detector with restricted degrees of freedom that moves along a linear path parallel to the calibration substrate. This dynamic configuration, combined with telecentric optics, maintains measurement precision throughout the scanning range while enabling automated high-speed calibration of multiple markings across the substrate surface.
Solution Approach 2:
The patent introduces telecentric optics as an intermediary between the detector and calibration substrate. The telecentric lens ensures that light rays from calibration markings travel parallel to the optical axis, eliminating perspective distortion and maintaining constant magnification across the entire field of view. This intermediary component enables precise measurements even with the detector's restricted movement.
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 significantly reduces calibration time and errors, achieving higher precision and accuracy, enabling the calibration of multiple laser processing devices in a fraction of the time required for manual methods while maintaining high measurement accuracy.
Implementation Method 1
The optical detector is configured for scanning a calibration substrate arranged on the scanning surface
Implementation Method 2
The scanning surface may be a transparent surface at least in part, such that when a calibration substrate is arranged on the scanning surface, the scanning surface may be arranged between the calibration substrate and the optical detector
Data Source
AI summary
A laser calibration device includes a scanning surface, an optical detector for scanning a calibration substrate arranged on the scanning surface, and a processing unit. The optical detector is movable with respect to the scanning surface with not more than two, preferably not more than one, degree of freedom. The processing unit is configured for: generating pattern generation executable instructions to generate a calibration pattern on a calibration substrate by one or more laser processing devices of a laser processing apparatus; detecting a calibration pattern generated based on such pattern generation executable instructions; and based on a detected calibration pattern and on the corresponding pattern generation executable instructions, generating calibration executable instructions for calibrating the one or more laser processing devices of said laser processing apparatus.