The present invention relates to a beam combining device configured to combine a plurality of laser light beams into one light flux and use the light flux and an output recovery method for the beam combining device, in particular, to redundancy using a spare light source (recovery function to be enabled at a time of failure in a light source) or the like.
For example, a related-art beam combining device of this kind, which is disclosed in PTL 1, has a configuration for combining a plurality of laser beams, in which optical fibers are respectively fixed to a plurality of laser light emitting unit that are provided, and those optical fibers are bundled to form a handle portion for the optical fibers.
[PTL 1] JP 5270949 B2 (page 4, line 50 to page 5, line 8 and FIG. 1 to FIG. 5)
Such a related-art beam combining device exhibits no degree of freedom when a plurality of laser beams are combined because each optical fiber is fixed to each laser light emitting unit. Therefore, for example, when a spare laser light emitting unit to be used at a time of failure is provided, there is a limitation on the number of beams that can be combined, and hence the spare laser light emitting unit occupies a part of the number of beams to be combined, which lowers an upper limit of a laser output.
The present invention has been made in order to solve the above-mentioned problem, and has an object to obtain a beam combining device and the like, which have the structure having a degree of freedom of combining a plurality of laser beams, and which are capable of adding a spare light source without lowering an upper limit of a laser output.
According to one embodiment of the present invention, there are provided a beam combining device and the like, including: a plurality of light sources; one or a plurality of spare light sources; a beam combining optical system configured to cause a beam combining element to combine beams from the respective light sources and the spare light source and to output the combined beams so that the beams having entered the beam combining optical system from the respective light sources and the spare light source are combined after passing through the beam combining element; a monitoring unit configured to monitor the beams from the respective light sources in order to detect a failure; and a light source switching unit configured to: move, when a failure in the light source is detected, at least a part of the respective light sources, the spare light source, and the beam combining optical system by a movable unit provided to at least a part of the respective light sources, the spare light source, and the beam combining optical system; cause a beam to enter the beam combining optical system from the spare light source instead of a beam from the failed light source; and cause the beam to be combined to beams from the plurality of light sources on an optical path after the beam combining element.
According to the present invention, the beam combining device and the like, which have the structure having the degree of freedom of combining the plurality of laser beams, and which are capable of adding the spare light source without lowering the upper limit of the laser output, can be provided.
Now, a beam combining device and the like according to each of embodiments of the present invention are described with reference to the drawings. In each of the embodiments, the same or corresponding portions are denoted by the same or corresponding reference symbols, and the overlapping description thereof is omitted.
The rail 3 may be provided to each of the LD packages 1a to 1e, and the folding mirror 2 may be moved individually. Further, there is provided a mechanism that enables the folding mirror 2 for the LD package 1e, the folding mirror 2 for the LD package 1b, and the folding mirror and others for the other LD packages to be moved manually or electrically from the outside of the casing 7, and the movement can be conducted without the opening of the casing 7. Further, it is desired that such a monitor mechanism (monitoring unit 102) as illustrated in
Specifically, the respective LD packages 1a to 1e are subjected to the adjustment and on/off of power supply from a power supply circuit. Further, the respective LD packages 1a to 1e each include a drive motor (not shown) configured to move the folding mirror 2 onto the rail 3. A light source switching function for those is illustrated as a light source switching mechanism 101. Further, a monitor device for a state of an LD package (configured to monitor a wavelength of a laser beam output from the LD package, an intensity (output) of a laser beam, an emission direction, a voltage at an LD of the LD package, and the like), for detecting a failure of the LD packages 1a to 1e, is illustrated as the monitoring unit 102. A control unit 100c formed of a computer or the like provided outside the casing 7 is connected to the light source switching mechanism 101 and the monitoring unit 102, and controls the light source switching mechanism 101 to control the on/off of the LD package (specifically, connection to and disconnection from the power supply circuit based on the on/off of power supply from the power supply circuit), the adjustment of the power supply, and the movement of the folding mirror 2 based on an input from an operator. Further, the control unit 100c determines a failed LD package based on the state of the LD package monitored by the monitoring unit 102.
The control unit 100c may be configured to determine the failed LD package based on the state of the LD package obtained from the monitoring unit 102, and to control the light source switching mechanism 101 based on a determination result to disconnect the failed LD package from the power supply circuit while connecting a spare LD package to the power supply circuit instead, and to further disconnect the folding mirror for the failed LD package from the optical path while moving the folding mirror for the spare LD package so that the optical path is superimposed on the optical path of the failed LD package.
Further, when the folding mirror 2 is manually moved, an operation rod having one end combined to the folding mirror 2 and the other end projecting outward through the casing 7 is manually operated by the operator.
With the beam combining device configured in the above-mentioned manner, it is possible to start the operation of a spare LD package instead of the LD package in which a failure has occurred without opening the casing 7.
The description of this embodiment is directed to the case where the LD bar is mounted to the LD package, but an LD chip may be a single chip.
Further, with respect to the number of LD packages, the description is directed to the case where four LD packages operate at startup with one spare LD package, but the numbers of LD packages and spare LD packages are not limited thereto. For example, a plurality of spare LD packages may be provided.
Further, in this embodiment, the diffraction grating 5 of a transmissive type is used as a dispersive medium (wavelength beam combining external resonator), but a device of the same kind (beam combining external resonator) can be configured in the case of any one of beam combining methods, such as wavelength beam combining, polarization beam combining, and spatial combining (positional combining).
Further, in a case where the light sources are combined into an optical fiber OP illustrated in
According to this embodiment, when a normal operation can no longer be conducted due to the lowering of an optical output from the LD package or other such causes, the normal operation can be continued by a spare LD package arranged within the casing starting an operation thereof. Further, during the normal operation, the spare LD package occupies none of optical paths of a wavelength beam combining external oscillator, and hence the limit of an output during the normal operation is not to be lowered due to the existence of the spare LD package. This produces an effect of, when the same number of LD packages are used, maintaining redundancy in that an alternative operation can be conducted using a spare LD package at a time of LD failure while ensuring the redundancy by leaving the optical path unoccupied without thereby lowering the limit of the output. Further, a device configured to automatically measure which LD package has failed is provided, to thereby be able to conduct the alternative operation without opening the casing. Therefore, it is possible to conduct such replacement as to avoid the influence of contamination or moisture.
In the light source switching mechanism 101 of
For example, the movable unit 1101 includes a mechanism for moving the folding mirror 2 onto the rail 3, and further includes, as illustrated in, for example,
The drive unit 1102 includes, for example, a drive motor for driving the above-mentioned movable unit, a power supply circuit for the LD package, and a power source for those.
As those specific components, suitable components may be selected and provided depending on the use form (the same applies below).
A part of the light source switching mechanism 101 may be preferably provided outside the casing 7 as described later, and is illustrated as a light source switching mechanism 111.
In
With the beam combining device configured in the above-mentioned manner, whichever of the LD packages 1f, 1g, and 1h fails, the LD package 1i, a cylindrical lens 11b therefor, and the movable mirrors 2a and 2b for the raising (parallel displacement of the optical path) are rotated and raised, to thereby replace the optical path of a failed LD package, and it is possible to start the operation of the spare LD package instead of the failed package.
Although not shown in detail in this embodiment, it is desired that, in the same manner as in the above-mentioned embodiment, for example, the control unit 100c, the light source switching mechanisms 101 and 111, and the monitoring unit 102 be provided to determine which of the LD packages 1f, 1g, and 1h has failed and to replace the failed LD package by the spare LD package 1i. The monitoring unit 102 of the failed LD package is a wavelength beam combining resonator, and hence a device configured to monitor a wavelength may be mounted, or a fiber terminal capable of coupling the existing wavelength measuring device only at a time of monitoring may be provided in order to cut the cost of a wavelength measuring device.
Further, the voltage of each LD package may be monitored. In addition, when the diffraction grating 5a from which zero-order light of the diffraction grating 5a leaks is used, the direction of leakage light may be monitored to detect which LD package has failed.
Further, it is desired that a monitoring unit automatically operate or the monitoring unit be provided outside the casing 7a, and that a mechanism for moving the movable unit and a mechanism for switching wirings so as to inhibit a current from flowing into the failed LD package and to cause a current to flow into the spare LD package be further provided outside the casing, to thereby enable the switching without the opening of the casing.
In this case, for example, the light source switching mechanism 101 moves the LD package 1i, the cylindrical lens 11b therefor, and the movable mirrors 2a and 2b for the raising (parallel displacement of the optical path) in the direction of rotation about the diffraction grating 5a, and raises the movable mirrors 2a and 2b. The LD package 1i, the cylindrical lens 11b, and the movable mirrors 2a and 2b are provided, for example, on movable support portions (not shown) each including a drive motor for causing the above-mentioned operation to be conducted, and the light source switching mechanism 101 controls the movable support portion to move. Further, in the same manner as in the above-mentioned embodiment, the adjustment and on/off of the power supply to each LD package are conducted. The monitoring unit 102 monitors the states of the LD packages 1f, 1g, and 1h. The control unit 100c determines the failed LD package based on a monitoring result of the state of the LD package obtained from the monitoring unit 102, and controls the light source switching mechanism 101 based on the determination result to disconnect the failed LD package (for example, 1h) from the power supply circuit while connecting the spare LD package 1i to the power supply circuit instead, and further rotates the LD package 1i, the cylindrical lens 11b therefor, and the movable mirrors 2a and 2b up to positions below the failed LD package and raises the movable mirrors 2a and 2b.
The detection result of the state of the LD package obtained from the monitoring unit 102 may be displayed on a display unit (not shown) of the control unit 100c, and the operator may determine the failed LD package based on the display and input to the control unit 100c an instruction to switch from the failed LD package to the spare LD package. Then, the light source switching mechanism 101 may conduct the above-mentioned switching operation in response to a control signal from the control unit 100c that is based on the input instruction.
Further, the monitoring unit 102 may be provided outside the casing 7a, and configured to receive, in a position outside the casing 7a, a detection signal from a sensor (not shown) configured to detect a wavelength of a laser beam within the casing, the intensity (output) of the laser beam, the emission direction, the voltage at the LD of the LD package, and the like. In another case, the casing 7a may be formed to be partially transparent, and the state of the laser beam that can be detected from a separate place may be monitored from the outside of the casing 7a. Further, in regard to the light source switching mechanism 101, as described also in the subsequent embodiments, wiring switching may be conducted between the connection and the disconnection of the LD package to/from the power supply circuit by providing a wiring switching box configured to conduct the wiring switching outside the casing 7a and conducting the on/off control manually or under the control signal from the control unit 100c with an electric switch provided to the wiring switching box. The same applies to the other embodiments.
With the beam combining device configured in the above-mentioned manner, at a time of failure in the LD package, the failed LD package can be replaced by the spare LD package, and hence it is possible to generate a larger output without the need to reserve the optical path for the spare LD package in advance. Further, at a time of the replacement, the operation can be conducted from the outside of the casing after the detection of a failed part, which can alleviate the influence of the failure due to contamination. Further, it is possible to reduce time and labor to be required for the replacement.
The LD packages 1f, 1g, and 1h being a plurality of light sources are arranged, for example, in a shape of a concentric circle about the diffraction grating 5a serving as the beam combining element. The LD package 1i serving as the spare light source moves along a trajectory exhibiting a concentric circle shape that has a radius smaller than those of the LD packages 1f, 1g, and 1h and is offset toward a direction perpendicular to a plane including the concentric circle.
For example, the movable unit of the light source switching mechanism 101 includes the movable support portions configured to movably support the LD package 1i, the cylindrical lens 11b, and the movable mirrors 2a and 2b as described above, and further includes, as illustrated in, for example,
Next,
Further, the spare LD package 1j has a gain sufficient to replace another LD within a wavelength range corresponding to the diffraction angle in an arrangement position illustrated in
Further, in
Further, the number of spare LD packages 1j does not need to be limited to one, and any number of spare LD packages 1j may be arranged depending on the redundancy to be required for the device.
Further, the operations relating to a capability of sharing the optical path between the diffraction grating 5a and the partially transmitting mirror 6b with another LD package, a capability of obtaining a predefined output and a predefined focusing property, and the like are adjusted in advance before the device starts to be used.
When the LD package 1g fails, the control unit 100c, which includes the monitoring unit 102 and the display unit configured to display the monitoring result, first detects and displays which LD package has failed. In a detection method for the failed LD package, as described in the second embodiment, the voltage of each LD package may be monitored, or the laser beam output from each LD package, the emission direction, the wavelength, and the like may be monitored. Further, only a light-receiving unit or a terminal for the monitoring may be provided, and may be connected to a fiber, a console, or a personal computer (PC) at a time of inspection. When it is detected and displayed which LD package has failed, as illustrated in
In this case, the current and the voltage may be adjusted by a power source PS of the power supply circuit illustrated in
In this embodiment, the wiring switching box 10 serving as a light source switching mechanism is provided outside the casing, and the wirings can be switched without the opening of the casing, which can prevent adverse influence of contamination or moisture from being exerted on optical elements and LD elements that are arranged within the casing. Further, the switching of the wirings and the monitoring can be conducted quickly, and hence it is possible to alleviate a load imposed on the operator in charge of maintenance. If possible, it is desired to automatically conduct any one of or both the detection of the failed LD package and the switching of the wirings.
That is, in the same manner as described in the above-mentioned embodiments, the control unit 100c determines the failed LD package based on the monitoring result of the state of the LD package obtained from the monitoring unit 102, outputs an open/close control signal to the electric switch SW configured to conduct the connection and disconnection of the wirings based on the determination result, the electric switch SW being provided on the wiring switching box 10 serving as a light source switching mechanism (including the movable unit and the drive unit) as exemplified in
To briefly describe
Hitherto, automatic switching of a current is easy when the current is small, but as in this embodiment, there is a case where it is difficult to automate the switching of a large current on the order of equal to or larger than several amperes with the device being increased in size, and hence the wiring switching box 10 may be provided outside the casing to provide a mechanism for manual switching. That is, the effects of the present invention are achieved to a large extent when the current that energizes the light source is a current exceeding one ampere.
In this embodiment, the wavelength beam combining external oscillator is formed by separately providing an optical path to a spare package, to thereby be able to continue a normal operation at the time of failure only by the switching of the wirings without providing the moving mechanism or the like unlike in the second embodiment. By omitting the moving mechanism, it is possible to achieve the downsizing of the device and the reduction of the time required for the replacement.
The spatial combining (positional combining) is briefly described with reference to
Next, as illustrated in
Next, the beams are further combined to one beam by the wavelength beam combining as illustrated in
In the beam combining device having the above-mentioned configuration, a failure does not always occur in each one of the LD packages (LDs) within one laser module as illustrated in
With the beam combining device configured in the above-mentioned manner, it is not necessary to provide one separate laser module as a spare, and it is possible to improve the redundancy of the entire beam combining device, and to continue the operation while maintaining a desired output even when one laser module stops. Further, the cost of providing one spare LD package to each laser module can be reduced when the number of LD packages included in one laser module is exceeded by the number of beams combined after being emitted from the laser modules.
In order to increase the number of beams to be combined, there is no other way than to increase the number of beams to be subjected to the spatial combining (positional combining) or the wavelength beam combining. When the number of beams to be subjected to the spatial combining (positional combining) is increased, the focusing property of the beams within the entire device is degraded. When the number of beams to be subjected to the wavelength beam combining is to be increased, it is necessary to increase the wavelength, which leads to an increase in cost and makes the maintenance more difficult. As understood from the above description, there is a limitation on the number of beams to be combined after being emitted from the laser modules, and in order to increase the output, it is more advantageous to increase the number of beams to be subjected to the wavelength beam combining through use of a diffraction grating or a dispersive optical element that serves as a beam combining element within the module. In the case of the wavelength beam combining device using the dispersive optical element, the effects of the present invention are achieved to a large extent.
Compared to a case of providing a spare laser module relating to a method of ensuring the redundancy, which is different from the present invention, it is possible to form the device with a smaller number of parts and to lower an occurrence probability of a failure. Further, it is possible to downsize the device.
Further, the possibility of handling various failures is expanded. For example, when one spare laser module is provided, it is conceivable that the spare laser module can no longer operate normally due to a failure, but as in this embodiment, when the output reduction of one laser module is compensated by another laser module as configured in this embodiment, it is possible to cover the failure even when one laser module is broken. Further, it is also possible to reduce the number of LD packages to be required to ensure the redundancy.
Further, as representatively illustrated by the broken lines in
Further, in this case, as described later, in order to compensate the output from the failed LD package, the laser control unit 100cc may be configured to control the control unit 100c of the corresponding laser module to conduct such control as to increase the output from a normal LD package, to thereby conduct such control as to increase the current supplied to the LD of the LD package controlled by the control unit 100c.
Further, the laser control unit 100cc may be configured to directly conduct the control (including output adjustment and wiring switching control through the wiring switching box 10) of all the laser modules and the LD packages without the intermediation of the control units 100c of the respective laser modules.
Further, the configuration of each laser module is not limited to the configuration according to the third embodiment, and may be the configuration including the spare LD package as described in another embodiment.
The above-mentioned wirings are equivalent to those of the LD package 1f disconnected from the power supply circuit. Further, in this case, the LD package 1f may be wired so as to be disconnected from the power supply circuit.
When the LD package stops operating, as illustrated in
Further, when the device configured so that an operation current value of the LD of the LD package has a limit of, for example, 60 A has a characteristic that the output increases depending on the current within a current range equal to or smaller than 60 A, the device may be operated in the following manner. That is, the device is kept operating with 40 A or 50 A at all times, and at a time of failure in the LD package, only the failed LD package is disconnected from the power supply circuit by the wiring switching, the current value is increased to, for example, 55 A or the like to ensure a required output, and the operation is continued until the maintenance can be conducted.
In this case, any spare LD package does not need to be mounted when the total number of LD packages is large enough to cover failures of several LD packages by increasing the current and when the possibility that one laser module may stop suddenly is extremely low. Further, the number of spare LD packages may be greatly reduced. That is, the number of spare LD packages can be reduced depending on a failure probability (frequency) and a severity level of a possible failure. When the redundancy is ensured with such a method, the number of LD packages to be required can be reduced, and the occurrence probability of a failure can be lowered. Further, it is possible to downsize the device.
In this manner, the casing of the LD packages and the optical parts is split, to thereby allow the LD package to be easily replaced. Further, in
Further, in
With such a configuration, at the time of replacement, the possibility that the LD package may be influenced by contamination or moisture can be lowered, and hence it is possible to increase the life of the LD package.
The LD packages 1i, 1j, and 1k may include a spare LD package.
The light beams emitted from the LD packages 1a, 1b, and 1c are combined into one beam between the output coupling element 6d and the dispersive optical element 5c, and extracted from the output coupling element 6d. Further, a part of the beams having entered the output coupling element 6d is returned to the LD packages 1a, 1b, and 1c via the dispersive optical element 5c. In this case, the part of the light beams from the LD packages 1a, 1b, and 1c enter the monitoring unit 102, and the lowering of the output can be detected when the lowering is determined based on, for example, a comparison with the intensity of the output signal at a normal time. At this time, the control unit 100c operates the light source switching mechanism 101 depending on the failed site based on the detection result of the failed site in the LD package 1a, 1b, or 1c obtained from the monitoring unit 102, so that an optical path connecting between the failed LD package and the dispersive optical element 5c is brought to a stopped state, and that an optical path connecting between the spare LD package 1e and the dispersive optical element 5c is brought to an operating state.
For example, when the LD package 1a fails, the folding mirrors 2A, 2E, and 2F are moved as illustrated in
Further, when the LD package 1b fails, the folding mirrors 2B and 2F are moved as illustrated in
Further, when the LD package 1c fails, the folding mirror 2C are moved as illustrated in
The spare LD package 1e is adjusted in advance by adjusting the folding mirrors 2D, 2E, and 2F under a state in which the folding mirrors 2A, 2B, and 2C have been removed, so that the wavelength beam combining external resonator can operate with any of the folding mirrors 2D, 2E, and 2F.
Although not shown in detail, the components may be arranged so that a distance between the spare LD package 1e and the dispersive optical element 5c and a distance between the LD packages 1a, 1b, and 1c and the dispersive optical element 5c are the same, and, for example, a lens (exemplified by the broken line in
The folding mirrors 2A to 2F are each configured to move on rails 3a and 3b or rotate about, for example, the center of the folding mirror by a drive motor (not shown).
Further, by providing the LD packages 1a, 1b, and 1c and the spare LD package 1e on a movement substrate 112 illustrated in
In the first embodiment described above (
the LD packages 1a to 1d form the light sources;
the LD package 1e forms the spare light source;
the diffraction grating 5 forms the beam combining element;
the folding mirror 2, the cylindrical lens 4, the diffraction grating 5, and the partially transmitting mirror 6 form a beam combining optical system;
the monitoring unit 102 forms the monitoring unit; and
the light source switching mechanisms 101 and 111 and the control unit 100c form a power source switching unit.
Further, the mechanism for moving the folding mirror 2 onto the rail 3, the electric switch SW having the mechanism for conducting the adjustment and on/off control of the power supply from the power supply circuit to the respective LD packages 1a to 1e, which is illustrated in, for example,
In the second embodiment described above (
the LD packages 1f, 1g, and 1h form the light sources;
the LD package 1i forms the spare light source;
the diffraction grating 5a forms the beam combining element;
the cylindrical lens 11, the movable mirrors 2a and 2b, the diffraction grating 5a, and the partially transmitting mirror 6a form the beam combining optical system;
the monitoring unit 102 forms the monitoring unit; and
the light source switching mechanism 101 and the control unit 100c form the power source switching unit.
Further, the movable support portions configured to movably support the LD package 1i, the cylindrical lens 11b, and the movable mirrors 2a and 2b, the electric switch SW having the mechanism for conducting the adjustment and on/off control of the power supply from the power supply circuit to the LD packages, which is illustrated in, for example,
In the third embodiment described above (
the LD packages 1f, 1g, and 1h form the light sources;
the LD package 1j forms the spare light source;
the diffraction grating 5a forms the beam combining element;
the cylindrical lens 11c, the diffraction grating 5a, and the partially transmitting mirror 6b form the beam combining optical system;
the monitoring unit 102 forms the monitoring unit;
the wiring switching box 10 forms the wiring switching box;
the casing 7b forms the casing; and
the control unit 100c (light source switching mechanism 101) forms the power source switching unit.
Further, when the light source is automatically controlled, the electric switch SW having the mechanism for conducting the adjustment and on/off control of the power supply from the power supply circuit to the LD package, which is illustrated in, for example,
In the fourth to sixth embodiments described above (
the laser modules 12a to 12h form the laser modules;
a spatial combining (positional combining) unit, a polarization beam combining unit, a wavelength beam combining unit, and a fiber coupling unit form a module beam combining optical system 500;
the laser monitoring unit 102a forms a laser monitoring unit; and
the laser control unit 100cc forms a laser control unit.
The configuration within each laser module is the same as the configuration of another embodiment.
In the seventh embodiment described above (
the LD packages 1i, 1j, and 1k form the light sources and the spare light sources;
the diffraction grating 5b forms the beam combining element;
the cylindrical lens 11c, the diffraction grating 5b, and the partially transmitting mirror 6c form the beam combining optical system;
the casing 7c forms a main casing;
the casing 18 (including each of the divided casings) forms sub-casings; and
the positioning members 19 form positioning units.
In the eighth embodiment described above (
the LD packages 1a to 1c form the light sources;
the LD package 1e forms the spare light source;
the folding mirrors 2A to 2E form the optical element;
the dispersive optical element 5c forms the beam combining element;
the output coupling element 6d forms the output optical element;
the folding mirrors 2A to 2E, the cylindrical lens 4, the dispersive optical element 5c, and the output coupling element 6d form the beam combining optical system;
the monitoring unit 102 forms the monitoring unit; and
the light source switching mechanism 101 and the control unit 100c form the power source switching unit.
Further, the mechanism for moving the folding mirrors 2A to 2E onto the rails 3a and 3b, the mechanism for moving the LD packages 1a to 1c onto the movement substrate 112, the electric switch SW having the mechanism for conducting the adjustment and on/off control of the power supply from the power supply circuit to the respective LD packages 1a to 1c, and 1e, which is illustrated in, for example,
Further, the present invention is not limited to the respective embodiments described above, and includes all possible combinations of those embodiments. Further, the light source switching of the beam combining device according to each of the embodiments may be conducted manually, or may be conducted automatically by a control unit or the like.
The configuration of the beam combining device according to the present invention can be applied to beam light sources in different kinds of fields.
Number | Date | Country | Kind |
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2014-015840 | Jan 2014 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2015/051663 | 1/22/2015 | WO | 00 |