This application claims priority to Japanese Patent Application No. 2022-078582, filed May 12, 2022, the disclosure of which is incorporated by reference herein in its entirety.
The present disclosure relates to a laser processing machine and a method of correcting a spot diameter of a laser processing machine.
Patent Document 1 discloses a technique for correcting the deviation of the focal position due to thermal lens effect in the laser processing machine.
Patent Literature 1: JP-07-051875 A
The protective glass provided in the laser head, fumes or spatter-derived dust generated during laser processing may adhere. When the laser head emits a laser beam in a state where dust is attached to the protective glass, the laser beam is scattered by the dust, the converging spot diameter at the processing point is increased, the processing quality is lowered. Therefore, as in the technique described in Patent Document 1, only by correcting the deviation of the focal position due to the thermal lens effect, it is impossible to sufficiently suppress a decrease in processing quality.
One aspect of the present disclosure provides a laser processing machine. The laser processing machine includes: a lens for condensing a laser beam; an actuator changing a relative position between the lens and a workpiece to change a focal position of the laser beam with respect to the workpiece; a protective glass disposed between the lens and the workpiece; a detector detecting a focal position of the laser beam; and a controller configured to control the actuator, the controller configured to obtain a current deviation amount of the focal position from a target position using the detector, the controller configured to obtain a relationship data, wherein the relationship data indicates relationship between a deviation amount of the focal position from the target position and a spot diameter of the laser beam on a surface of the workpiece when contaminant adheres the protective glass, the controller configured to estimate a current spot diameter of the laser beam on the surface using the current deviation amount and the relationship data, the controller configured to control the actuator to correct the current spot diameter using the current deviation amount and an estimated current spot diameter.
In the present embodiment, the laser processing machine 10 includes a laser oscillator 100, a laser head 200, a head supporting unit 300, a stage 400, and a controller 500. The stage 400, the workpiece WK is fixed.
The laser oscillator 100 generates the laser beam LS. In the present embodiment, the laser beam LS generated by the laser oscillator 100 is a fiber laser. In other embodiments, the laser beam LS generated by the laser oscillator 100 may be, for example, a solid-state laser other than a fiber laser such as a disk laser or a semiconductor laser or a YAG laser. The laser beam LS generated by the laser oscillator 100 is not a solid-state laser, for example, may be a gas laser such as a carbon dioxide laser.
The laser oscillator 100 is connected to the laser head 200 by an optical fiber 150. The laser beam LS generated by the laser oscillator 100 is transmitted from the laser oscillator 100 to the laser head 200 by optical fibers 150. When the laser beam LS to be generated by the laser oscillator 100 is a carbon dioxide laser, rather than the optical fiber 150, it is preferable that the laser beam LS is transmitted from the laser oscillator 100 to the laser head 200 by the bend mirror.
The laser head 200 includes a collimator lens 210, a dichroic mirror 220, a first reflecting mirror 230, a focal position changing unit 240, a second reflecting mirror 250, a condenser lens 260, an irradiation position changing unit 270, and a protective glass 280. The laser beam LS introduced from the optical fiber 150 to the laser head 200 is converted into a collimated light by the collimator lens 210, is reflected toward the first reflecting mirror 230 by the dichroic mirror 220, the focus position changing unit by the first reflecting mirror 230 It is reflected toward the focal position changing unit 240. The laser beam LS passing through the focal position changing unit 240 is reflected toward the condenser lens 260 by the second reflecting mirror 250. The laser beam LS condensed by the condenser lens 260 is guided to the protective glass 280 by the irradiation position changing unit 270, is emitted toward the workpiece WK through the protective glass 280. In
The focal position changing unit 240 includes a Z lens 241, and a Z lens driving unit 242. Z lens 241 is disposed on the path of the laser beam LS between the first reflecting mirror 230 and the second reflecting mirror 250. In
The irradiation position changing unit 270 includes an X mirror 271, X mirror driving unit 272, Y mirror 276, and a Y mirror driving unit 277. X mirror 271 and Y mirror 276 is disposed on the path of the laser beam LS between the condenser lens 260 and the protective glass 280. X mirror drive unit 272, by changing the orientation of the X mirror 271 changes the irradiation position of the laser beam LS on the workpiece WK in the X-axis. Y mirror drive unit 277, by changing the orientation of the Y mirror 276 changes the irradiation position of the laser beam LS on the workpiece WK in the Y-axis. The X mirror driving unit 272 and the Y mirror driving unit 277, for example, a motor can be used.
The protective glass 280 is disposed on the path of the laser beam LS between the irradiation position changing unit 270 and the workpiece WK. The protective glass 280 protects various components provided in the laser head 200 from fumes and spatters generated during the welding process. The various components include, for example, condenser lens 260, X mirror 271, and Y mirror 276. In the present embodiment, the protective glass 280 is made of quartz glass on which an antireflection film is formed.
The laser head 200 includes the return light detector 290. The return light detector 290 includes a third reflecting mirror 291, and a photodetector 292. Some of the laser beam LS emitted from the laser head 200 is reflected by the surface of the workpiece WK, it returns to the laser head 200. In the following explanation, the laser beam LS returning to the laser head 200 is referred to as return beam. Return light introduced into the laser head 200 through the protective glass 280 includes an irradiation position changing unit 270, a condenser lens 260, a second reflecting mirror 250, a focal position changing unit 240, a first reflecting mirror 230 in this order through, is guided to the dichroic mirror 220. The return light is transmitted through the dichroic mirror 220 and is introduced into the return light detector 290. The third reflecting mirror 291 reflects toward the photodetector 292 the return light introduced into the return light detector 290. The photodetector 292 receives the return light and outputs an electrical signal representing the intensity of the return light. Electrical signals output from the photodetector 292 is transmitted to the controller 500. In
The head supporting unit 300 supports the laser head 200. In the present embodiment, the head supporting unit 300 has a function of changing the irradiation position of the laser beam LS on the workpiece WK by changing the position of the laser head 200. In the present embodiment, the head supporting unit 300 is constituted by a robot arm. In other embodiments, the head supporting unit 300 may be constituted by a fixing jig having no function of changing the position of the laser head 200.
The controller 500 comprises a computer comprising a CPU501, a memory 502, an input/output interface 503, and an internal bus 504 interconnecting the two. In the present embodiment, the controller 500 controls the laser oscillator 100, the Z lens driving unit 242 of the focal position changing unit 240, the X mirror driving unit 272 and the Y mirror driving unit 277 of the irradiation position changing unit 270, and the head supporting unit 300. Incidentally, the memory 502 is sometimes referred to as a storage unit.
In this embodiment, the controller 500 includes a processing execution unit 510, an inspection execution unit 520, a deviation amount acquiring unit 530, a spot diameter estimating unit 540, and a correction execution unit 550. The processing execution unit 510, the inspection execution unit 520, the deviation amount acquiring unit 530, the spot diameter estimating unit 540, and the correction execution unit 550 are implemented in software by CPU501 executing a computer program stored in the memory 502. The controller 500 may be configured by a combination of a plurality of circuits, rather than a computer.
The processing execution unit 510, by irradiating a laser beam LS on the workpiece WK from the laser head 200, executes the welding of the workpiece WK. The processing execution unit 510, by controlling the focal position changing unit 240, the focal position of the laser beam LS becomes a target position determined in advance, and the spot diameter of the laser beam LS at the surface of the workpiece WK is adjusted to be a target diameter determined in advance. The processing execution unit 510, by controlling the irradiation position changing unit 270, while moving the irradiation position of the laser beam LS on the workpiece WK, subjected to weld machining on the workpiece WK. The processing execution unit 510, as the focal position of the laser beam LS is positioned on the laser head 200 side with respect to the surface of the workpiece WK, and controls the focal position changing unit 240. The processing execution unit 510, the temperature of the optical element such as a condenser lens 260 provided in the laser head 200 starts the welding process after stable.
The inspection execution unit 520, the laser beam LS of low power as compared with the time of processing is irradiated to the workpiece WK from the laser head 200, the strength of the return light measured by the photodetector 292 of the return light detector 290 to inspect the weld quality of the workpiece WK. Specifically, the inspection execution unit 520, the waveform of the intensity of the return light measured by the photodetector 292, compared with the reference waveform previously stored in the memory 502, to determine the quality of the weld quality of the workpiece WK. The reference waveform, it is possible to use a waveform of the intensity of the return light obtained by irradiating a laser beam LS of low power to good from the laser head 200.
The deviation amount acquiring unit 530, using the return light detector 290, acquires the deviation amount from the target position of the focal position of the laser beam LS. In the following description, the deviation amount from the target position of the focal position is referred to as a focus shift amount. The focus shift amount is a positive value when the focal position is shifted in a direction from the workpiece WK to the laser head 200, a negative value when the focal position is shifted in a direction from the workpiece WK to the laser head 200. The method of obtaining the focus shift amount will be described later. The spot diameter estimating unit 540 estimates the current spot diameter using the current focus shift amount acquired by the deviation amount acquiring unit 530 and a table TB representing the relation between the focus shift amount and the spot diameter of the laser beam LS previously stored in the memory 502. The correction execution unit 550, in the spot diameter correction process, executes a correction of the current spot diameter of the laser beam LS.
In
In
Next, in a step S120, the spot diameter estimating unit 540 estimates the current spot diameter of the laser beam LS at the processing point using the focus shift amount obtained by the deviation amount acquiring unit 530 and the relational data. The relationship data is a data representing the relationship between the focus shift amount and the spot diameter when the contaminant M is attached to the protective glass 280. The relationship data is previously stored in the memory 502. In the present embodiment, the table TB shown in
In a step S130, the correction execution unit 550, as the current spot diameter of the laser beam LS at the processing point is the same as the target diameter, and corrects the current spot diameter. In the present embodiment, the correction execution unit 550, by moving the focal position F of the laser beam LS using the focal position changing unit 240, corrects the current spot diameter of the laser beam LS at the processing point. Correction execution unit 550, a first movement amount L1 for moving the focal position F so that the focus shift amount becomes zero, the focal position F further so that the focal position F as the focal diameter at the processing point from the position where the focus shift amount becomes zero in the sum amount of the second movement amount L2 for moving, to move the focal position F. Thereafter, the correction execution unit 550 ends the spot diameter correction process. Incidentally, the method performed by the spot diameter correction process is sometimes referred to as a spot diameter correction method of the laser processing machine 10. The step S110 of the spot diameter correction process is referred to as a deviation acquiring process, the step S120 is referred to as a spot diameter estimation process, the step S130 is sometimes referred to as a correction executing process.
As shown in (B) in
As shown in (C) in
As shown in (D) in
According to the laser processing machine 10 in the present embodiment described above, the controller 500, by executing the spot diameter correction process, it is possible to correct the deviation of the spot diameter due to the contaminant M is attached to the protective glass 280. Therefore, by spot diameter at the processing point deviates from the target diameter, and the quality of processing using the laser beam LS, it is possible to suppress the accuracy of the inspection using the return light is lowered.
Further, in the present embodiment, the table TB stored in the memory 502, as the focus shift amount in the direction from the workpiece WK toward the laser head 200 is increased, it is represented that the spot diameter at the processing point increases. Therefore, as the degree of contamination of the protective glass 280 is large, with the focus shift amount in the direction from the workpiece WK toward the laser head 200 is increased by the thermal lens effect, the spot diameter at the processing point by the scattering phenomenon of the laser beam LS by utilizing the phenomenon that increases, it is possible to appropriately correct the spot diameter at the processing point.
In the present embodiment, the correction execution unit 550, a first movement amount L1 for moving the focal position F so that the focus shift amount becomes zero, the focal position F so that the spot diameter at the processing point from the position where the focus shift amount becomes zero is the target diameter in the total amount of the second movement amount L2 for further moving, to move the focal position F. Therefore, even without moving the focal position F by dividing twice, it is possible to correct the spot diameter in the movement of one focal position F. Therefore, it is possible to shorten the correction of the spot diameter.
Further, in the present embodiment, the deviation amount acquiring unit 530 acquires the focus shift amount using the return light detector 290. Therefore, the acquisition of the focus shift amount can be automated.
(B1) In the first embodiment described above, the correction execution unit 550, in the spot diameter correction process, by changing the position of the Z lens 241 by the Z lens driving unit 242 of the laser head 200, the focal position F of the laser beam LS by changing the distance between the workpiece WK, to correct the spot diameter of the laser beam LS at the processing point. In contrast, the correction execution unit 550, the spot diameter correction process, by changing the position of the laser head 200 by the head supporting unit 300, by changing the distance between the focal position F and the workpiece WK of the laser beam LS, the laser beam at the processing point it may be corrected spot diameter of LS. In this case, the head supporting unit 300 is referred to as a focal position changing unit. Alternatively, lifting device driven under the control of the controller 500 is provided on the stage 400, by changing the distance between the focal position F and the workpiece WK by the lifting device, the laser beam LS in the processing point it may be corrected spot diameter. In this case, the lifting device provided in the stage 400 is referred to as a focus position changing unit.
(B2) In the first embodiment described above, the laser processing machine 10, the return light detector 290 is provided with a photodetector 292. In contrast, it may not be returned to the laser processing machine 10 photodetector 290 is provided. In this case, the deviation amount acquiring unit 530, for example, may acquire the focus shift amount input by the user.
The disclosure is not limited to any of the embodiment and its modifications described above but may be implemented by a diversity of configurations without departing from the scope of the disclosure. For example, the technical features of any of the above embodiments and their modifications may be replaced or combined appropriately, in order to solve part or all of the problems described above or in order to achieve part or all of the advantageous effects described above. Any of the technical features may be omitted appropriately unless the technical feature is described as essential in the description hereof. The present disclosure may be implemented by aspects described below.
(1) In one aspect of the present disclosure, a laser processing machine is provided. The laser processing machine includes: a lens for condensing a laser beam; an actuator changing a relative position between the lens and a workpiece to change a focal position of the laser beam with respect to the workpiece; a protective glass disposed between the lens and the workpiece; a detector detecting a focal position of the laser beam; and a controller configured to control the actuator, the controller configured to obtain a current deviation amount of the focal position from a target position using the detector, the controller configured to obtain a relationship data, wherein the relationship data indicates relationship between a deviation amount of the focal position from the target position and a spot diameter of the laser beam on a surface of the workpiece when contaminant adheres the protective glass, the controller configured to estimate a current spot diameter of the laser beam on the surface using the current deviation amount and the relationship data, the controller configured to control the actuator to correct the current spot diameter using the current deviation amount and an estimated current spot diameter.
According to the laser processing machine of this form, it is possible to correct the change in spot diameter at the processing point caused by contaminants adhere to the protective lens. Therefore, it is possible to suppress a decrease in processing quality of the laser processing by the laser processing machine.
(2) According to the laser processing machine of the above aspect, the relationship data may represent that the spot diameter increases as the deviation amount increases from the workpiece toward the lens.
According to the laser processing machine of this form, the greater the degree of contamination of the protective glass is focal position in a direction away from the workpiece by the thermal lens effect is increased, the greater the degree of contamination of the protective glass is the laser beam scattering phenomenon spot diameter is increased, utilizing the phenomenon that can appropriately correct the spot diameter.
(3) According to the laser processing machine of the above aspect, the controller may be configured to control the actuator so that the focal position moves a total distance of a first distance and a second distance to correct the current spot diameter, wherein the first distance may be a distance for moving the focal position so that the current deviation amount to be zero, wherein the second distance may be a distance for moving the focal position from the position where the current deviation amount is zero so that the spot diameter on the surface to be a target diameter.
According to the laser processing machine of this form, even without moving the focal position of the laser beam divided into two, it is possible to correct the focal diameter of the laser beam in the movement of one focal position. Therefore, it is possible to shorten the correction of the focal diameter of the laser beam.
(4) According to the laser processing machine of the above aspect, the detector may include a photodetector for receiving the laser beam reflected from the workpiece, the controller may be configured to obtain the current deviation amount using intensity of the laser beam measured by the photodetector.
According to the laser processing machine of this form, it can automate the acquisition of the current deviation amount of the focal position of the laser beam.
(5) In one aspect of the present disclosure, a method of correcting a spot diameter of a laser processing machine is provided. The laser processing machine including a protective glass for protecting a lens. The method includes: obtaining a current deviation amount of a focal position of the laser beam from a target position, wherein the laser beam is irradiated on a surface of a workpiece through the lens and the protective glass; estimating a current spot diameter of the laser beam on the surface using the current deviation amount and a relationship data, wherein the relationship data indicates the relationship between the deviation amount and the spot diameter when contaminant adheres the protective glass; and changing a relative position between the lens and the workpiece using the current deviation amount and the estimated current spot diameter to correct the current spot diameter.
According to the spot diameter correction method of this form, it is possible to correct the change in the focal diameter at the processing point caused by contaminants adhere to the protective lens. Therefore, it is possible to suppress a decrease in processing quality of the laser processing by the laser processing machine.
The present disclosure, a laser machine, it is also possible to realize in various forms other than the method of correcting a spot diameter of a laser processing machine. For example, it can be realized in the form of a laser processing method.
Number | Date | Country | Kind |
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2022-078582 | May 2022 | JP | national |