The present invention relates to a laser irradiation state determination method (method for determining laser irradiation state) for determining a state of a laser irradiation device in accordance with an output of a laser emitted by the laser irradiation device.
JP 6279589 B2 and JP 6021929 B2 disclose techniques for measuring laser output of a laser irradiation device.
The techniques disclosed in JP 6279589 B2 and JP 6021929 B2 do not take into account the fact that the output characteristics at the rising edge immediately after the start of laser irradiation differ from one laser irradiation device to another. Therefore, there is a problem in that the accuracy of the obtained laser output is low.
The present invention has been made to solve the above-described problem, and an object thereof is to provide a laser irradiation state determination method capable of acquiring an output of a laser with high accuracy.
According to an aspect of the present invention, there is provided a laser irradiation state determination method for determining an irradiation state of a laser beam emitted by a laser irradiation device, the method including: an output stabilization time acquisition step of acquiring, as an output stabilization time, a time from when the laser irradiation device starts irradiation of the laser beam to when an output of the laser beam is stabilized; an energy acquisition step of acquiring energy of the laser beam irradiated by the laser irradiation device for a predetermined time period set in advance, after the output stabilization time or more has elapsed since the laser irradiation device started the irradiation of the laser beam; a conversion step of converting the acquired energy into the output of the laser beam irradiated by the laser irradiation device; and a state determination step of determining the irradiation state of the laser beam based on the converted output of the laser beam.
According to the present invention, it is possible to obtain output of a laser beam with high accuracy.
The laser brazing machine 10 includes a brazing material supply device 20, a laser irradiation device 22, and a transfer robot 24.
The brazing material supply device 20 reels out a wire-shaped brazing material 14 from a reel (not shown), and supplies the brazing material 14 from a guide 26 to a portion to be joined 28 between the roof panel 16 and the side panel 18.
The laser irradiation device 22 irradiates the brazing material 14 supplied to the portion to be joined 28 with a laser beam from an irradiation head 30. The irradiation head 30 is connected to a laser oscillator (not shown) via a transmission cable. The brazing material 14 is melted by the energy of the laser, and then the brazing material 14 is cooled and solidified to form a bead 32. The roof panel 16 and the side panel 18 are joined by the bead 32. A protective glass 31 is provided at a portion, of the irradiation head 30 of the laser irradiation device 22, from which a laser beam is emitted.
The transfer robot 24 is a robot that transfers the brazing material supply device 20 and the laser irradiation device 22. The transfer robot 24 moves the brazing material supply device 20 and the laser irradiation device 22 along the portion to be joined 28 of the vehicle body 12. Further, the transfer robot 24 moves the laser irradiation device 22 above a laser output sensor 34. The laser irradiation device 22 emits a laser beam toward the laser output sensor 34. The laser output sensor 34 detects the output of the laser beam. Based on the detected laser output, a laser irradiation state determination unit 44 described later determines the laser irradiation state of the laser irradiation device 22. The measurement of the laser output of the laser irradiation device 22 is performed each time the machining of one vehicle body 12 is completed. The measurement of the laser output of the laser irradiation device 22 may be performed every time before the machining of one vehicle body 12 is started. The laser output sensor 34 is covered with a protective glass 35.
The output stabilization time acquisition unit 38 acquires an output stabilization time from laser output information detected by the laser output sensor 34. The output stabilization time is a time from the start of laser irradiation by the laser irradiation device 22 to the stabilization of the laser output. The output stabilization time will be described later in detail.
The energy acquisition unit 40 acquires the energy of the laser beam emitted by the laser irradiation device 22 for a predetermined time period from the laser output information detected by the laser output sensor 34. The process of acquiring laser energy will be described later in detail.
The output conversion unit 42 converts the laser energy acquired by the energy acquisition unit 40, into the laser output. An output conversion process for converting the laser energy into the laser output will be described later in detail.
The laser irradiation state determination unit 44 determines the laser irradiation state of the laser irradiation device 22 based on the laser output obtained by the output conversion unit 42. The determination process of the laser irradiation state of the laser irradiation device 22 will be described later in detail.
The notification control unit 46 controls a notification unit 48 based on the laser irradiation state of the laser irradiation device 22 determined by the laser irradiation state determination unit 44, and performs notification to the operator. The notification unit 48 may be a display device that displays characters, images, or the like, or may be an acoustic device that emits sound or the like.
The output stabilization time acquisition unit 38, the energy acquisition unit 40, the output conversion unit 42, the laser irradiation state determination unit 44, and the notification control unit 46 are realized by a processor executing a program stored in a storage medium (not illustrated).
As shown in
When the change in laser output of the laser irradiation device 22 with respect to time changes as shown in the graph of
In step S1, the energy acquisition unit 40 determines whether or not the output stabilization time or more has elapsed since the laser irradiation device 22 started the laser irradiation. If the output stabilization time or more has elapsed, the process proceeds to step S2. If the output stabilization time has not elapsed, the determination of step S1 is repeated.
In step S2, the energy acquisition unit 40 acquires, as energy, a value obtained by integrating the laser output detected, by the laser output sensor 34, for a predetermined time period ΔT2 [ms] which is set in advance, and ends the energy acquisition process.
After the output stabilization time T0 [ms] or more has elapsed from the start of laser irradiation by the laser irradiation device 22, the energy acquisition unit 40 acquires, as energy, the value obtained by integrating the laser output for a predetermined time period ΔT2 [ms]. When the laser output varies as shown in
In step S11, the output conversion unit 42 inputs the laser energy acquired by the energy acquisition unit 40, and then the process proceeds to step S12.
In step S12, the output conversion unit 42 converts the laser energy into the laser output, and ends the output conversion process. When the laser output changes as shown in
In step S21, the laser irradiation state determination unit 44 inputs the laser output obtained by the output conversion unit 42, and the process proceeds to step S22.
In step S22, the laser irradiation state determination unit 44 determines whether the laser output input in step S21 is less than a preset threshold value or not. When the laser output is less than the threshold value, the process proceeds to step S23. When the laser output is equal to or greater than the threshold value, the process proceeds to step S24.
In step S23, the notification control unit 46 controls the notification unit 48 to notify the operator that the output of the laser irradiation device 22 has decreased, and the laser irradiation state determination process is terminated.
In step S24, the notification control unit 46 controls the notification unit 48 to notify the operator that the output of the laser irradiation device 22 is normal, and the laser irradiation state determination process is terminated.
In the conventional laser output acquisition method, the laser output is acquired based on energy obtained by integrating the laser output from immediately after the laser irradiation device 22 starts laser irradiation. The laser output sensor 34 of the present embodiment has high responsiveness, and can detect a change in laser output during laser irradiation of several milliseconds. Therefore, the energy of the laser irradiated for a short period of time can be obtained, and the laser output can be obtained in a short period of time. However, a period during which the laser output is not stable makes up a relatively large proportion of the entire period during which the laser energy is obtained, and there is a problem in that the accuracy of the laser output converted from the obtained laser energy reduces.
In a case where the laser output varies as illustrated in
In the case where the laser output changes as shown in
In general, when the laser output is obtained based on the energy of the laser irradiated for a time period as long as possible, the obtained laser output has higher accuracy. However, in the present embodiment, in consideration of the characteristics of the laser output sensor 34, the output is acquired based on the energy of the laser beam irradiated for a short time period excluding a time period during which the laser output is not stable. Accordingly, the laser output can be obtained with high accuracy, and the accuracy of the determination of the laser irradiation state of the laser irradiation device 22 based on the laser output can be improved.
The laser irradiation state determination device 36 according to the present embodiment specifically determines the cause of the decrease in output of the laser irradiated by the laser irradiation device 22 from time-series data of the laser output of the laser irradiation device 22 obtained by the output conversion unit 42.
The laser irradiation state determination device 36 includes an output stabilization time acquisition unit 38, an energy acquisition unit 40, an output conversion unit 42, a time-series data storage unit 50, a laser irradiation state determination unit 44, and a notification control unit 46. Among these components, the output stabilization time acquisition unit 38, the energy acquisition unit 40, and the output conversion unit 42 are the same as the output stabilization time acquisition unit 38, the energy acquisition unit 40, and the output conversion unit 42 of the first embodiment. The laser irradiation state determination unit 44 and the notification control unit 46 are partially different from the laser irradiation state determination unit 44 and the notification control unit 46 of the first embodiment in the contents of processing to be performed. The time-series data storage unit 50 is a constituent element added in the present embodiment.
Each time the laser irradiation state of the laser irradiation device 22 is determined, the time-series data storage unit 50 stores, as time-series data, the laser output obtained by the output conversion unit 42 in association with the time at which the laser irradiation state of the laser irradiation device 22 is determined.
The laser irradiation state determination unit 44 determines the laser irradiation state of the laser irradiation device 22 based on the time-series data stored in the time-series data storage unit 50. The laser irradiation state determination process of the laser irradiation device 22 will be described later in detail.
The notification control unit 46 controls the notification unit 48 based on the laser irradiation state of the laser irradiation device 22 determined by the laser irradiation state determination unit 44, and performs notification to the operator.
The output stabilization time acquisition unit 38, the energy acquisition unit 40, the output conversion unit 42, the laser irradiation state determination unit 44, and the notification control unit 46 are realized by a processor executing a program stored in a storage medium (not illustrated). The time-series data storage unit 50 is realized by a storage medium (not shown).
In step S31, the laser irradiation state determination unit 44 inputs the laser output obtained by the output conversion unit 42, and the process proceeds to step S32.
In step S32, the laser irradiation state determination unit 44 stores the laser output input in step S31 in the time-series data storage unit 50 as time-series data in association with the sequential order in which the laser output is input, and then the process proceeds to step S33.
In step S33, the laser irradiation state determination unit 44 acquires the time-series data of laser output from the time-series data storage unit 50, and the process proceeds to step S34.
In step S34, the laser irradiation state determination unit 44 determines the laser irradiation state of the laser irradiation device 22 based on the time-series date, and the process proceeds to step S35. The determination process of the laser irradiation state of the laser irradiation device 22 based on the time-series data will be described later in detail.
In step S35, the notification control unit 46 controls the notification unit 48 to notify the operator of the laser irradiation state of the laser irradiation device 22 determined in step S34, and the laser irradiation state determination process ends.
An air knife is provided on the surface of the protective glass 31 of the irradiation head 30 of the laser irradiation device 22. The air knife prevents spatters and fumes from entering the protective glass 31 side. However, in some cases, spatters or fumes may pass through the air knife to enter the protective glass 31 side and adhere to the protective glass 31. When the spatter or fume adheres to the protective glass 31, the laser output irradiated by the laser irradiation device 22 decreases. The change of the time-series data differs depending on whether what is attached to the protective glass 31 is the spatter or the fume, and further depending on the main component of the spatter.
The time-series data in
By irradiating the brazing material 14 with the laser, fine particles (spatters) of zinc or copper contained in the brazing material 14 are scattered. Spatters containing zinc as the main component have a relatively low melting point. The spatters containing zinc as the main component adheres to the protective glass 31 and thereafter is burned and spread by heat of the laser. Therefore, the laser output gradually decreases over several tens of vehicle bodies after the spatters containing zinc as the main component have been attached to the protective glass 31. The laser irradiation state determination unit 44 determines that spatters containing zinc as the main component are attached to the protective glass 31 in a case where the laser output gradually decreases over several tens of vehicle bodies, as shown in the time-series data illustrated in
The size of the spatter containing copper as the main component is larger than the size of the spatter containing zinc as the main component. Therefore, when spatters containing copper as the main component adhere to the protective glass 31, the output of the laser is greatly reduced. When the output of the laser decreases stepwise as shown in the time-series data in
The time-series data of
The time series data of
As shown in the time-series data of
The time-series data of
In both the time series data (
In the present embodiment, the laser output of the laser irradiation device 22 acquired by the output conversion unit 42 is stored as time-series data in the time-series data storage unit 50. Then, the laser irradiation state determination unit 44 determines the laser irradiation state of the laser irradiation device 22 based on the stored time-series data. As a result, it is possible to perform more detailed determination on the laser irradiation state.
The inventions that are capable of being grasped from the above-described embodiments will be mentioned below.
There is provided a laser irradiation state determination method for determining an irradiation state of a laser beam emitted by a laser irradiation device (22), the method including: an output stabilization time acquisition step of acquiring, as an output stabilization time, a time from when the laser irradiation device starts irradiation of the laser beam to when an output of the laser beam is stabilized; an energy acquisition step of acquiring energy of the laser beam irradiated by the laser irradiation device for a predetermined time period set in advance, after the output stabilization time or more has elapsed since the laser irradiation device started the irradiation of the laser beam; a conversion step of converting the acquired energy into the output of the laser beam irradiated by the laser irradiation device; and a state determination step of determining the irradiation state of the laser beam based on the converted output of the laser beam. As a result, it is possible to obtain the output of the laser with high accuracy, and it is possible to improve the accuracy of determination by determining the irradiation state of the laser based on the highly accurately obtained output of the laser.
In the laser irradiation state determination method described above, the output stabilization time may be set in advance. As a result, since the process of obtaining the output stabilization time is not performed during machining, a load imposed on the laser irradiation state determination device 36 can be reduced.
In the above-described laser irradiation state determination method, the state determination step may determine the irradiation state of the laser beam by comparing the converted output of the laser beam with a preset threshold value. By determining the irradiation state of the laser by comparing the acquired output of the laser with the threshold value, it is possible to easily determine the irradiation state of the laser.
The laser irradiation state determination method may further include a time-series data storage step of storing the converted output of the laser beam as time series data, and the state determination step may determine the irradiation state of the laser beam on the basis of the time series data. As a result, it is possible to perform more detailed determination on the laser irradiation state.
Number | Date | Country | Kind |
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2019-110024 | Jun 2019 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2020/022663 | 6/9/2020 | WO | 00 |