Tool Setter Beam Profile Checking for Accurate Laser Measurement
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Solution Overview
Problem
Non-contact tool setting apparatus in machine tools face reduced measurement accuracy due to contaminants and environmental factors affecting the laser beam width, necessitating frequent cleaning and maintenance, which increases downtime.
Innovation Solution
A method and apparatus for assessing the beam profile by moving an object with an edge through the light beam, determining the beam profile using the beam intensity signal at multiple positions, and fitting a mathematical function to the collected intensity values to measure beam width, allowing regular checks without disrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the non-contact tool setting apparatus is used in a dirty environment with coolant and swarf, then the apparatus can perform tool measurements, but the beam width changes due to thermal growth and laser wavelength changes, reducing measurement accuracy
Solution Approach 1:
The patent performs preliminary characterization of the laser beam profile under actual operating conditions before using it for measurements. By measuring the beam width and intensity distribution in advance using a translation stage and photodetector, the system establishes baseline parameters that account for thermal growth and wavelength changes, thereby improving subsequent measurement accuracy
Solution Approach 2:
The patent monitors and compensates for changes in laser beam parameters (width, intensity distribution) that occur during operation due to thermal effects and wavelength drift. By continuously tracking these parameter changes and adjusting measurements accordingly, the system maintains measurement precision despite operating in a dirty environment
2Measurement precision
If the tool setting apparatus is cleaned regularly to remove contaminants, then measurement accuracy is maintained, but machine tool downtime increases
Solution Approach 1:
The patent implements a self-diagnosis capability where the system automatically detects beam profile changes and determines whether cleaning is needed, eliminating the need for manual inspection and reducing downtime. The automated beam characterization system serves itself by monitoring its own performance degradation
Solution Approach 2:
The patent uses feedback from beam intensity measurements to determine when cleaning is required. By continuously monitoring beam profile changes and comparing them against thresholds, the system provides feedback that triggers cleaning only when necessary, optimizing the balance between maintaining accuracy and minimizing downtime
3Duration of action of stationary object
If the laser beam width is allowed to change due to thermal growth and wavelength changes, then the apparatus operates continuously without interruption, but the reliability of tool measurements decreases
Solution Approach 1:
The patent performs preliminary beam characterization under actual operating conditions to establish baseline parameters before continuous operation begins. This advance preparation allows the system to account for thermal growth and wavelength changes that will occur during continuous operation, maintaining measurement reliability throughout the operational period
Solution Approach 2:
The patent actively monitors and compensates for parameter changes in the laser beam during continuous operation. By tracking beam width and intensity distribution changes and adjusting measurements in real-time, the system maintains measurement reliability even as thermal effects and wavelength drift occur during extended operation
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 quick and accurate measurement of beam width, minimizing downtime by allowing regular checks and adjustments, ensuring reliable tool measurements without the need for frequent cleaning or recalibration.
Implementation Method 1
a light source which generates a beam of light which is passed to a detector
Implementation Method 2
The receiver detects (e.g. using a photodiode) the received light and generates a beam intensity signal describing the intensity of the received light
Data Source
Figure 1
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AI summary
A method and an apparatus are described for assessing the beam profile of a light beam (12) of a non-contact tool setting apparatus. The non-contact tool setting apparatus comprises a transmitter (10) for emitting the light beam and a receiver (14) for receiving the light beam (12). The receiver (14) generates a beam intensity signal describing the intensity of received light. The non-contact tool setting apparatus is mounted to a machine tool having a spindle that is moveable relative to the non-contact tool setting apparatus. The method comprises loading an object having an edge into the spindle of the machine tool and using the machine tool to move the spindle relative to the non-contact tool setting apparatus so that the edge of the object passes through the light beam (12). The beam profile of the light beam (12) is then determined using the beam intensity signal generated at a plurality of positions during the step (ii) of moving the edge of the object through the light beam (12).