Patent Grant
10901162
The disclosure pertains to back-reflection protection in fiber and fiber-delivered laser systems.
High-power industrial laser systems generally produce beams having output powers in the range of several hundreds of Watts to several kW. It is often desirable to deliver the laser power to a processing head or work piece via an optical fiber. Laser systems that can be coupled into an optical fiber for delivery include fiber lasers, disk lasers, and diode- or lamp-pumped solid-state lasers (e.g., Nd:YAG). In these systems, the desired optical power is guided in the fiber core, but some power may also be present in the fiber cladding; this cladding light is undesirable because it can cause excessive heating of or damage to downstream components or optics, or it may otherwise interfere with work piece processing.
In typical fiber laser systems a signal beam is created in an active fiber that includes a rare-earth doped optical fiber core by delivering a pump beam to a cladding of the active fiber at a pump wavelength that is shorter than a signal beam wavelength. At the output of the fiber laser, cladding light may consist of unabsorbed pump light and signal light that has escaped from the core. For both fiber lasers and other lasers, cladding light may be introduced into a beam delivery fiber if launching of the laser beam couples some of the light into the cladding rather than the core. A processing beam directed to a target or work piece can experience reflection or scattering and can become back-coupled into the beam delivery fiber. This back-coupled light can be coupled into both the active or beam delivery fiber core and cladding, and can destabilize, damage, or otherwise interfere with the laser system.
Accordingly, systems that can remove and monitor both forward-propagating and backward-propagating cladding light and backward-propagating core light are needed, particularly to protect against high-power back-reflections.
According to one aspect a system includes an optical fiber situated to propagate a laser beam received from a laser source to an output of the optical fiber, a first cladding light stripper optically coupled to the optical fiber and situated to extract at least a portion of forward-propagating cladding light in the optical fiber, and a second cladding light stripper optically coupled to the optical fiber between the first cladding light stripper and the optical fiber output and situated to extract at least a portion of backward-propagating cladding light in the optical fiber.
According to another aspect, a method includes directing a material processing laser beam from a laser source from an output end of a beam delivery fiber to a target, receiving a returned portion of the material processing laser beam returned from the target, coupling the returned portion into the beam delivery fiber, extracting cladding light associated with the material processing laser beam in a first cladding light stripper optically coupled to the beam delivery fiber, and extracting cladding light associated with the returned portion of the material processing laser beam in a second cladding light stripper optically situated between the first cladding light stripper and the output end of the beam delivery fiber.
According to another aspect, a method includes detecting a characteristic associated with backward-propagating cladding light extracted with a cladding light stripper from a beam delivery fiber delivering a laser beam generated with a laser source, detecting a characteristic associated with backward-propagating core light in the beam delivery fiber, and adjusting one or more laser system characteristics in response to one or more of the detected backward-propagating cladding light and backward-propagating core light characteristics.
According to another aspect, a system includes a first cladding light stripper disposed between a laser source and a beam delivery fiber output situated in relation to a target, the first cladding light stripper situated to receive a material processing beam and to extract forward-propagating cladding light associated with the material processing beam from the beam delivery fiber, and a second cladding light stripper disposed between the first cladding light stripper and the beam delivery fiber output and situated to receive the material processing beam from the first cladding light stripper and to receive backward-propagating cladding light associated with the target, the second cladding light stripper situated to extract backward-propagating cladding light from the beam delivery fiber.
According to another aspect, a laser feedback monitoring system in a high-power laser system is provided, the high-power laser system configured to produce a laser beam from a laser source and to emit the laser beam from a delivery fiber output and to direct the emitted beam to a target, with the laser feedback monitoring system including a first cladding light stripper situated between the laser source and the delivery fiber output to receive the laser beam and to remove cladding light associated with the beam, a second cladding light stripper situated between the first cladding light stripper and the delivery fiber output to receive the beam from the first cladding light stripper and to remove residual cladding light associated with the beam and to receive light back-reflected from the target and coupled back into the delivery fiber output and to remove back-reflected cladding light, and at least one back-reflected cladding light detector coupled to the second cladding light stripper for detecting characteristics of the back-reflected cladding light.
The foregoing and other objects, features, and advantages will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” does not exclude the presence of intermediate elements between the coupled items.
The systems, apparatus, and methods described herein should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed systems, methods, and apparatus are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed systems, methods, and apparatus require that any one or more specific advantages be present or problems be solved. Any theories of operation are to facilitate explanation, but the disclosed systems, methods, and apparatus are not limited to such theories of operation.
Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed systems, methods, and apparatus can be used in conjunction with other systems, methods, and apparatus. Additionally, the description sometimes uses terms like “produce” and “provide” to describe the disclosed methods. These terms are high-level abstractions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art.
In some examples, values, procedures, or apparatus' are referred to as “lowest”, “best”, “minimum,” or the like. It will be appreciated that such descriptions are intended to indicate that a selection among many used functional alternatives can be made, and such selections need not be better, smaller, or otherwise preferable to other selections. Examples are described with reference to directions indicated as “above,” “below,” “upper,” “lower,” and the like. These terms are used for convenient description, but do not imply any particular spatial orientation.
As used herein, optical radiation refers to electromagnetic radiation at wavelengths of between about 100 nm and 10 μm, and typically between about 500 nm and 2 μm. Examples based on available laser diode sources and optical fibers generally are associated with wavelengths of between about 800 nm and 1700 nm. In some examples, propagating optical radiation is referred to as one or more beams having diameters, asymmetric fast and slow axes, beam cross-sectional areas, and beam divergences that can depend on beam wavelength and the optical systems used for beam shaping. For convenience, optical radiation is referred to as light or beams in some examples, and need not be at visible wavelengths. Forward-propagating light or optical beams or beam portions refer to light, beams, or beam portions that propagate in a common direction with a processing beam that is directed to a target. Backward-propagating light or optical beams or beam portions refer to light, beams, or beam portions that propagate in a common and opposite direction of a processing beam that is directed to a target.
Representative embodiments are described with reference to optical fibers, but other types of optical waveguides can be used having square, rectangular, polygonal, oval, elliptical or other cross-sections. Optical fibers are typically formed of silica (glass) that is doped (or undoped) so as to provide predetermined refractive indices or refractive index differences. In some, examples, fibers or other waveguides are made of other materials such as fluorozirconates, fluoroaluminates, fluoride or phosphate glasses, chalcogenide glasses, or crystalline materials such as sapphire, depending on wavelengths of interest. Refractive indices of silica and fluoride glasses are typically about 1.5, but refractive indices of other materials such as chalcogenides can be 3 or more. In still other examples, optical fibers can be formed in part of plastics. In typical examples, a doped waveguide core such as a fiber core provides optical gain in response to pumping, and core and claddings are approximately concentric. In other examples, one or more of the core and claddings are decentered, and in some examples, core and cladding orientation and/or displacement vary along a waveguide length.
As used herein, numerical aperture (NA) refers to a largest angle of incidence with respect to a propagation axis defined by an optical waveguide for which propagating optical radiation is substantially confined. In optical fibers, fiber cores and fiber claddings can have associated NAs, typically defined by refractive index differences between a core and cladding layer, or adjacent cladding layers, respectively. While optical radiation propagating at such NAs is generally well confined, associated electromagnetic fields such as evanescent fields typically extend into an adjacent cladding layer. In some examples, a core NA is associated with a core/inner cladding refractive index, and a cladding NA is associated with an inner cladding/outer cladding refractive index difference. For an optical fiber having a core refractive index ncore and a cladding index nclad, a fiber core NA is NA=√{square root over (n2core−n2clad)}. For an optical fiber with an inner core and an outer core adjacent the inner core, a cladding NA is NA=√{square root over (n2inner−n2outer)}, wherein ninner and nouter are refractive indices of the inner cladding and the outer cladding, respectively. Optical beams as discussed above can also be referred to as having a beam NA which is associated with a beam angular radius. While multi-core step index fibers are described below, gradient index designs can also be used.
In the examples disclosed herein, a waveguide core such as an optical fiber core is doped with a rare earth element such as Nd, Yb, Ho, Er, or other active dopants or combinations thereof. Such actively doped cores can provide optical gain in response to optical or other pumping. As disclosed below, waveguides having such active dopants can be used to form optical amplifiers, or, if provided with suitable optical feedback such as reflective layers, mirrors, Bragg gratings, or other feedback mechanisms, such waveguides can generate laser emissions. Optical pump radiation can be arranged to co-propagate and/or counter-propagate in the waveguide with respect to a propagation direction of an emitted laser beam or an amplified beam.
The term brightness is used herein to refer to optical beam power per unit area per solid angle. In some examples, optical beam power is provided with one or more laser diodes that produce beams whose solid angles are proportional to beam wavelength and beam area. Selection of beam area and beam solid angle can produce pump beams that couple selected pump beam powers into one or more core or cladding layers of double, triple, or other multi-clad optical fibers.
Referring now to
A returned beam portion 24 that is coupled into the output of the delivery fiber 16 is generally undesirable and can destabilize the laser system 10 or cause laser system degradation and failure. By arranging a pair of cladding light strippers, such as the first and second cladding light strippers 20, 22, laser systems such as the laser system 12 can be provided with robust protection from back-reflection. In particular, the second cladding light stripper 22, which is more proximal to the output of the delivery fiber 16 as shown in
The cladding light strippers 20, 22 can also be conveniently arranged in close proximity to each other and still retain optical or thermal isolation. For example, in some embodiments, the cladding light strippers 20, 22 can be separated and separately or jointly cooled or otherwise thermally managed. In other embodiments, the cladding light strippers 20, 22 are disposed on a common heat sink block 26 which is actively cooled with one or more cooling devices coupled to the heat sink block 26. Depending on the design of the cladding light strippers 20, 22, forward-propagating cladding light may also be partially removed by the second cladding light stripper 22, and backward-propagating cladding light may also be partially removed by the first cladding light stripper 20. Forward-propagating cladding light is generally undesirable because it can cause heating or damage to components downstream from the fiber laser, e.g., to the delivery cable or to optical systems employed to deliver the laser beam to the work piece.
Depending on the output power of the output beam 14 (which can be as little as 0.5 kW or less to as much as 10 kW or more) and other attributes of the high-power laser system 10, various forward-propagating cladding light and back-coupled light power contents can be expected during operation. For example, the laser system 10 configured to generate the output beam 14 with an output power of around 3 kW can include 300 W or more of forward-propagating cladding light that should be coupled out of the delivered beam 14 and dissipated to prevent system destabilization. Theoretically, up to the entirety of the output beam 14 could be back-reflected and coupled back into the output of the delivery fiber 16, though 100% back-coupling may be unlikely. With the 3 kW output beam 14, in typical examples approximately 300 W can be expected to become back-coupled, however the portion of the output beam 14 that is back-reflected, the variability of the portion, and the time dependence of the portion can be dependent on the application in which the high-power laser system output beam 14 is being used. Accordingly, back-coupled light and backward-propagating cladding light can range from being continuous to highly transient. In some system examples, 100 W or more of continuous forward-propagating cladding light is removed and 100 W or more of transient backward-propagating cladding light is removed. The cladding light strippers 20, 22 are thus operable to remove the cladding light and the removed light can be dumped in some manner, such as with a conductive sink like conductive block 26.
Referring now to
The laser system 40 also includes a stripped forward-propagating cladding light detector 58 coupled to the first cladding light stripper 50. The detector 58 is situated to detect one or more characteristics associated with the forward-propagating cladding light, such as power, wavelength, temporal characteristics (e.g., power variation, pulse duration, pulse repetition rate), temperature in proximity to the stripper 50, etc., and provides an associated detection signal to a system controller 60. The detector 58 can include one sensor for detecting a particular characteristic, one sensor for detecting a plurality of characteristics, or a plurality of sensors for detecting the same or different characteristics. In some examples, the first cladding light stripper 50 includes a volume formed in the conductive block 56, such as an integrating volume. The forward-propagating cladding light propagates along a fiber situated in the volume, such as a portion of the beam delivery fiber 46 or another fiber or fiber portion coupled to the beam delivery fiber 46. One or more sensors associated with the detector 58 can be situated in or near the volume so as to generate detection signals to detect forward-propagating cladding light characteristics. To moderate detected characteristics of cladding light, one or more optical filters may be used. Detected characteristics can also include specular or diffuse reflections of cladding light extracted from the optical fiber in which the forward-propagating cladding light is propagating.
The laser system 40 further includes a stripped backward-propagating cladding light detector 62 coupled to the second cladding light stripper 52 which detects one or more characteristics associated with the backward-propagating cladding light, such as power, wavelength, temporal characteristics, temperature, etc. In some examples, the detector 62 (and/or detector 58) can include one or more of a thermistor, thermal switch, and photodiode. The output of the detector 62 is also coupled to the controller 60. Because most or all of the forward-propagating cladding light associated with the beam 44 is removed by the forward-propagating cladding light stripper 50, the detector 62 is situated to detect back-reflected characteristics without the characteristics becoming tainted, skewed, or muddled by the forward-propagating cladding light energy. Similarly, since most or all of the backward-propagating cladding light energy is removed by the backward-propagating cladding light stripper 52, the process of detecting forward-propagating cladding light characteristics experiences improved accuracy in the presence of back-reflected light.
The system controller 60 is situated to receive one or more such detection signals that can be associated with corresponding beam characteristics and can initiate different system actions in response. For example, controller 60 is shown to be coupled with control output 64 to laser source 42. Based on the detected characteristics from detectors 58, 62, a laser interlock procedure can be executed that triggers a power disconnect or an adjustment of power level or some other characteristic associated with the laser system 40, including the laser source 42 and the output beam 44. For example, if the backward-propagating cladding light power or an associated temperature is excessive, the laser source 42 can be turned off, or a warning can be issued to the user. Abnormal increases or decreases of the forward-propagating cladding power may indicate a malfunction of the laser system, which can result in turning off the laser source 42 or issuing a warning to a user. In other examples, laser source 42 output power can be varied to compensate for a detected variation in forward-propagating cladding energy. Other laser system characteristics can be adjusted as well, including cooling system characteristics (e.g., fluid flow-rates, power level, etc.).
The cladding light strippers 50, 52 typically couple only cladding light, or poorly coupled cladding light, out of the optical delivery fiber 46. Both the forward- and backward-propagating core light associated with beam propagation in the delivery fiber 46 is generally unaffected. Backward-propagating core light can also lead to system degradation and failure, and the system controller 60 can be coupled to a backward-propagating core light detector 66, that is coupled to the laser source 42 and detects one or more characteristics associated with backward-propagating core light. The interlock control 64 of the controller 66 can also be configured to disconnect or adjust power or another laser system characteristic associated with the laser source 42. In some embodiments, detected cladding light and core light characteristics can include spectral characteristics, allowing deeper insights into system operation and particular application effects, and enabling a spectral-based interlock for the system 40 or spectral-based adjustment of laser system characteristics, including output beam power, pump source power, and temporal features.
In some examples, a detector 68 is coupled to the optical fiber 46 propagating the output beam 44 between the first and second cladding light strippers 50, 52. Because most or all of the forward and backward-propagating cladding light is removed by the strippers 50, 52, the length of optical fiber 46 extending between the strippers 50, 52 provides a location suitable to detect characteristics of core light associated with the propagating output beam 44 such that detection experiences less interference associated with forward or backward cladding light energy. In one example, a core light power characteristic is detected with detector 68 coupled to a core light detection chamber 70 without interfering with propagating beam 44 by receiving light scattered out of the core. The light detection chamber 70 can serve as an optical integrating volume such that detector 68 receives a multiply reflected, integrated characteristic of the scattered core light. In another example, the detector 68 is coupled so as to directly receive the scattered core light or one or more mirrors or lenses can be used to concentrate and direct the scattered core light to the detector 68. In a further example, an optical splice is disposed on the optical fiber 46 in the detection chamber 70. The detector 68 can then detect optical loss associated with the propagation of light through the optical splice, and such loss can vary in relation to the optical power and wavelength of the beam 44 propagating in the core of the fiber. It will be appreciated that various features of detectors 58, 62, 68 as well as the detected characteristics can be used together.
In various examples, values of particular detected optical characteristics can provide the actual or close to the actual characteristic sought, or the values can be empirically or observationally matched to different expected or actual characteristics. For example, the laser system can be operated at selected power levels and an output beam can be measured both in the presence and absence of cladding light strippers or other system components to determine the amount of cladding light that is removed and corresponding detected values. A table can be generated, and a function fitted to the table values, associating the different detected characteristics in relation to the actual characteristics.
Cladding light strippers can be made in a variety of ways. Some examples of cladding light strippers utilize an epoxy that surrounds an exposed cladding surface of an optical fiber in which an output beam and cladding light are propagating. Because the fiber cladding is coupled to an epoxy with selected refractive index and other characteristics, cladding light is successively stripped along the length of the epoxy-cladding interface. In other examples of cladding light strippers, the optical fiber includes one or more notches or other patterns (“microstructures”) penetrating the circumference of the exposed cladding. The notches are operable to disrupt the propagating cladding light by directing the cladding light away from and out of the optical fiber without substantially affecting the light propagating in the fiber core. The out-coupled cladding light then impacts an adjacent surface of a conductive block and is eventually converted to heat, which dissipates through the conductive block. In other examples of cladding light strippers, silica-based crystals are formed on the cladding surface to scatter the cladding light out of the fiber without substantially affecting the light propagating in the fiber core.
Referring to
Laser source 102 is expanded to show an example of a laser source herein suitable for generating the high power fiber-coupled output beam 104. It will be appreciated that a variety of types and variations of laser sources are possible that can be configured to produce a fiber-delivered high power output beam, including laser sources configured to detect different operating system characteristics and to receive different control commands. Other examples of suitable laser sources include fiber lasers, fiber amplifiers, disk lasers, diode-pumped solid-state lasers, lamp-pumped lasers, and direct-diode lasers, each of which can be configured to operate at a wavelength that can be transmitted to the processing head or work piece using an optical fiber.
As shown, the exemplary laser source 102 includes a plurality of pump modules 118 that produce pump beams at a pump wavelength and couple the pump beams into a pump delivery fiber 120. The plurality of pump delivery fibers 120 is coupled to a pump or pump-signal combiner 122 which combines received pump light into a combined pump output 124. The output 124 is coupled to a fiber laser oscillator 126 that generates the output beam 104 in an active core of the fiber oscillator using the coupled pump light. The pump delivery fibers 120 are arranged in various configurations about an input of the combiner 122. An additional fiber 128 is coupled to a center position of the input of the combiner 122 and can be coupled to one or more components, including an aiming laser 130, a detector 132, or a beam dump 134. The aiming laser 130 emits an aiming beam which can assist with the use of the system 100 by showing the expected location for the beam 104 at the target 108. The center position occupied with the additional fiber 128 is also convenient for detection and removal of core light that is not contained by the oscillator 126. In particular, back-reflected light 116 that is coupled into the core of the delivery fiber 106 may not be removed by the cladding light strippers 110, 112 and can propagate through to the laser source 102.
The core detector 132 is thus situated to detect characteristics associated with core light propagating past the combiner 122 and to provide the detected characteristics to a system controller 136. Based in part or in whole on the received characteristics, the controller 136 can adjust other system characteristics, such as the power level supplied to the pump modules 118 using controller output 138, in order to protect or enhance system 100 performance. Moreover, the central position of the fiber 128 of the combiner 122 ensures most or all of the core light received by the combiner 122 from the direction of the oscillator 126 is directed into the fiber 128, which can then be detected with core light detector 132 and removed with beam dump 134. A detector 140 which detects forward-propagating cladding light is coupled to the first cladding light stripper 110 and provides information about forward-propagating cladding light characteristics to the controller 136. A detector 142 which detects backward-propagating cladding light is coupled to the second cladding light stripper 112 and provides information about backward-propagating cladding light characteristics to the controller 136. Independently or in concert, the detectors 132, 140, 142 can detect beam and system characteristics that can be utilized to optimize, protect, or otherwise enhance performance of laser system 100.
In
In view of the many possible embodiments to which the principles of the disclosed technology may be applied, it should be recognized that the illustrated embodiments are only representative examples and should not be taken as limiting the scope of the disclosure. Alternatives specifically addressed in these sections are merely exemplary and do not constitute all possible alternatives to the embodiments described herein. For instance, various components of systems described herein may be combined in function and use. We therefore claim all that comes within the scope and spirit of the appended claims.
This application is a continuation of U.S. application Ser. No. 14/816,211, filed Aug. 3, 2015, which claims the benefit of U.S. Provisional Application No. 62/032,043, filed on Aug. 1, 2014, both of which are hereby incorporated by reference in their entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20200064573 A1 | Feb 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62032043 | Aug 2014 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14816211 | Aug 2015 | US |
| Child | 16417337 | US |
