Workpiece Position Detection by Reflectivity in Laser Machining
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Solution Overview
Problem
Current methods for determining the position of hairpins in laser machining processes, such as laser welding, face challenges with precision due to factors like changing light conditions and metallic reflective surfaces, making it difficult to achieve robust and reproducible position recognition.
Innovation Solution
A method using a photodiode to determine the position of workpieces by analyzing reflected radiation from a measurement beam, which differentiates between the workpiece and the support device based on reflectivity, allowing for precise positioning and gap measurement between hairpins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera-based optical methods are used for component posture recognition, then the system can determine position and posture of hairpins, but the measurement precision deteriorates due to changing light conditions and metallic reflective surfaces
Solution Approach 1:
The invention changes the measurement parameter from intensity-based optical detection (camera) to time-based flight time measurement. By measuring the time of flight of light pulses rather than relying on light intensity and color information, the system becomes immune to lighting conditions and surface reflectivity variations, thereby improving both measurement precision and reliability
Solution Approach 2:
The invention replaces the mechanical/optical camera-based detection system with a time-of-flight measurement system. This substitution uses flight time information of light pulses instead of optical intensity patterns, eliminating the sensitivity to environmental light conditions and metallic surface reflections that plagues camera-based systems
2Measurement precision
If OCT systems are used for posture recognition, then the measurement precision improves by measuring intervals in three-dimensional space, but the device complexity and cost increase
Solution Approach 1:
The invention extracts only the essential measurement capability needed - the time of flight information - from the complex OCT system. By using a simplified time-of-flight approach with photodiodes and light pulses rather than full OCT technology, the system achieves comparable three-dimensional position measurement precision with significantly reduced device complexity and cost
Solution Approach 2:
The invention replaces expensive, complex OCT systems with simpler, more affordable time-of-flight measurement components such as photodiodes and LED or laser light sources. This substitution maintains the essential measurement functionality while dramatically reducing system cost and complexity
3Ease of operation
If camera-based systems are used for position determination, then the ease of operation is maintained, but the measurement precision deteriorates in challenging environments with metallic surfaces and varying light conditions
Solution Approach 1:
The invention replaces the camera-based optical detection system with a time-of-flight measurement system using photodiodes. This substitution measures the time for light pulses to travel to and from the hairpin surfaces, providing accurate position determination that is independent of lighting conditions and surface reflectivity, thereby maintaining ease of operation while improving measurement precision in challenging environments
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 easy, quick, and precise determination of workpiece position, even in challenging environments, improving the accuracy of laser machining processes and reducing errors in welding joints.
Implementation Method 1
A method using a photodiode to determine the position of workpieces by analyzing reflected radiation from a measurement beam
Implementation Method 2
A method using a photodiode to determine the position of workpieces by analyzing reflected radiation
Data Source
AI summary
A method for determining a position of a workpiece for a laser machining process includes the steps of: radiating a measurement beam to at least one workpiece and a support device surrounding the workpiece along at least one first and along at least one second measurement path, the first path forming a predetermined angle with the second path; acquiring a portion of the radiated measurement beam, reflected by the support device and the workpiece, along the first and along the second measurement path and generating a corresponding measurement signal, the support device and the workpiece comprising a reflectivity different from each other; and determining a position of the workpiece based on the measurement signal. A method for machining a workpiece by a laser beam includes the method for determining the position of the workpiece. An apparatus for determining a position of a workpiece is configured for conducting the methods.