In laser processing systems, a laser beam is used to heat an area on a piece of working material. This localized heating is used to bond pieces together, to mark pieces and/or to cut pieces, for example. The laser beam is focused and steered to a selected point on the working material using optics that include lenses and mirrors. In some laser processing systems, the working material is described as being in an x,y plane and the optics include a galvo having two rotatable mirrors that are used to steer the beam to different positions in the x,y plane. The beam is focused to a focal point by two or more lenses, where the focal point is the position along the beam where the beam has a minimum waist or cross section. The distance from the output of the galvo to the position of the focal point is referred to as the focal length.
If the position of the galvo is static, a fixed focal length causes the focal point to move along a spherical path as the galvo changes the x,y position of the beam. To see this, imagine a string that is as long as the focal length of the beam. If one end of the string is fixed to the output of the galvo, the other end of the string will follow a spherical path as it is moved in the x-y directions. This is undesirable because the working material is generally planar and moving the focal point along a spherical surface will cause the focal point to move out of the plane of the working material resulting in less efficient processing of the working material.
To overcome this, the art uses dynamic focusing in which different focal lengths are assigned to different x,y positions so that the focal points of all of the x,y positions are in a common plane, referred to as the focal plane.
The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background.
A laser beam is applied to optics to focus the laser beam into a focal point substantially on a piece of working material. An expected shift in a focal plane due to heating of the optics by the laser beam is determined. At least one feature of the optics is altered based on the expected shift so as to maintain the focal point substantially on the piece of working material.
In a further embodiment, an apparatus includes a laser producing a laser beam during operation and an optics servo capable of moving at least one optical element that the laser beam is incident upon during operation. A controller causes the optics servo to move the at least one optical element to compensate for a change in a focal point due to heat generated by the laser beam during operation.
In a further embodiment, a controller for a laser-based manufacturing device is provided that includes storage electronics and control electronics. The storage electronics receive and store a power level of a laser beam. The control electronics use the stored power level of the laser beam to set a servo control signal such that when the servo control signal is provided to an optics servo the servo control signal causes the optics servo to move an optics element to compensate for a change in a focal point of the laser beam due to heating.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
To ensure that the laser beam size, focal point size and laser beam intensity are adequate for a selected laser processing application, beam enhancement module 108 is in optical communication with optics. In laser processing system 100, the optics include two high-reflection mirrors 110 and 112 that are in optical communication with each other. The first mirror is in optical communication with beam enhancement module 108, while the second mirror is in optical communication with a servo-driven expansion lens 114. The servo-driven expansion lens 114 is in optical communication with a beam focusing lens or objective lens 116. Servo-driven expansion lens 114 and objective lens 116 together form focusing optics that are able to dynamically change the focal length of the laser beam. In particular, a focus servo controller 150 provides control signals to a focus servo 115, also referred to as an optics servo 115, to move expansion lens 114 relative to objective lens 116 to thereby alter the focal length of the laser beam. As discussed further below, focus servo controller 150 sets the control signal based on an x-y position for the beam provided by controller 102 and a focal plane shift compensator 802. In accordance with some embodiments, servo 115 is linear drive motor with a rotary actuator that moves lens 114 by closed loop control. The position of lens 114 is monitored during laser processing and focus servo controller 150 uses the position as feedback to accurately set the focal point so that all of the focal points remain in a single plane, referred to as a focal plane.
Objective lens 116 is in optical communication with a beam steering system, also referred to as a galvo 118 that includes a pair of servo-driven mirrors 120 and 122, which are movable to steer the beam in two separate dimensions. For convenience, the two dimensions are referred to as x,y. The servo-driven mirrors are moved by two respective servos in response to control signals produced by an x-y servo controller 152, which produces the control signals based on an x-y position for the beam provided by controller 102. The output of galvo 118 is a laser beam 129 that is focused on an x,y point 130 on working material 124. Working material 124 can be moved by one or more conveyors 126 and 128 and may include areas that are to be melted, bonded, marked and/or cut, for example, by beam 129.
Thus, in operation, laser 104 produces a laser beam 106 that is enhanced by beam enhancement module 108 and then reflected off mirrors 110 and 112 to servo-driven lens 114. Servo-driven lens 114 expands the beam provided by minor 112 and the expanded beam is then narrowed by objective lens 116. The output beam from objective lens 116 reflects off servo-driven mirrors 120 and 122 so that it is focused at x-y point 130 on working material 124. By setting different x-y points, controller 102 is able to change the location of x-y point 130.
If servo-driven expansion lens 114 is maintained at a static position for all x-y positions of the laser beam, the focal point for the laser beam will follow a spherical surface as shown by spherical surface 200 of
Laser beam 106 generated by laser 104 generally has a Gaussian distribution for its beam intensity. As shown in
The uneven heating of the optics changes the refractive characteristics of one or more of the optical elements, such as the lenses and mirrors, that the laser beam is incident upon between laser 104 and material 124. These changes cause a shift in the focal plane from plane 202 to focal plane 206 as shown in
Because the focal plane shift is due to heating from the laser beam, the size of the focal plane shift is dependent on the time over which the laser beam has been applied to the optics and the power of the laser beam.
Embodiments described below provide techniques for automatically compensating for focal plane shift due to laser-based optic heating. The technique includes two parts. In the first part, the curves shown in
At step 504, test controller 600 starts a timer 604 and at step 506, laser controller 103 turns on laser 104 using laser power level 602. Timer 604 provides a series of time values to test controller 600, each separated by a time interval. At step 508, for each time value, focal height monitor 610 provides a focal plane shift value to test controller 600. Focal height monitor 610 determines the shift in the focal plane by measuring the waist of the laser beam at multiple vertical positions to determine the location of the waist minimum and thus the location of the focal plane. In accordance with other embodiments, focal height monitor 610 measures the waist of the laser beam at a single vertical position and uses an equation to convert the change in the size of the waist of the laser beam into a shift in the height of the focal plane.
At step 510, test controller 600 stores the set of time values and corresponding focal plane shift values for the power level selected at step 500 as time/focal plane shift curve 612. Time/focal plane shift curve 612 may be stored as a set of time values/focal plane shift values or may be stored as an equation that describes the focal plane shift values as a function of time.
At step 512, the process determines if there are more power levels to be considered. If there are more power levels, the process returns to step 500 and a new power level is selected. Steps 502-510 are then repeated. When there are no more power levels at step 512, the process of setting time/focal plane shift curves 612 is complete.
At step 514, a parameter identifier 614 uses time/focal plane shift curves 612 to identify an average thermal constant parameter. Each of the time/focal plane shift curves 612 has an associated thermal constant parameter that describes the shape of the curve. Parameter identifier 614 determines the thermal constant parameter for each curve and then averages those parameters to form the average thermal constant parameter, which is then stored in focal plane shift parameters 616.
At step 516, parameter identifier 614 uses time/focal plane shift curves 612, a laser meter calibration value, and a motion scale value to identify a scaling factor parameter. In particular, parameter identifier 614 uses time/focal plane shift curves 612 to identify a slope for each curve, where the slope is the ratio of a binary value representing the offset of the focal plane over a measure of the power of the laser. Parameter identifier 614 averages these slope values to form an average slope that is then multiplied by the laser meter calibration factor representing the ratio of actual laser power over measured laser power and by the motion scale value representing the ratio of an offset distance over a binary value representing the offset distance. The resulting product is the scaling factor parameter, which is also stored in focal plane shift parameters 616. At step 518, the process of
In step 700 of
At step 702, focal plane shift identifier 808 of focal plane shift compensator 802, also referred to as control electronics 802, retrieves focal plane shift parameters 612, including average thermal constant and scaling factor.
At step 704, focal plane shift identifier 808 waits for a focal plane adjustment time to arrive. In accordance with one embodiment, focal plane adjustments are made at fixed intervals such as at a frequency of 50 Hz or once every 0.02 seconds, for example.
When the focal point adjustment time arrives, focal plane shift identifier 808 receives a current laser power level at step 705. Specifically, focal plane shift identifier 808 receives the current measured laser power level from laser meter 800, which measures the power of the laser output by laser 104. The received laser power level is stored in storage electronics that can form part of control electronics 802 or may be separate from control electronics 802.
At step 706, focal plane shift identifier 808 uses the current laser power, a previous weighted sum of past laser powers and the average thermal constant of the retrieved focal plane shift parameters to form a new weighted sum of laser powers. In particular, the average thermal constant is used to weight the previous weighted sum of past laser powers less than the current laser power when forming the new weighted sum of laser powers. The new weighted sum of laser powers is stored in storage electronics (memory) to be used during the next focal plane adjustment time as the previous weighted sum.
At step 707, focal plane shift identifier 808 uses the scaling factor of the retrieved focal plane shift parameters and the new weighted sum of laser powers to determine the expected focal plane shift 811. In accordance with one embodiment, the expected focal plane shift 811 is formed as the product of the scaling factor and the new weighted sum of laser powers. The expected focal plane shift 811 is provided to focus servo controller 150.
At step 708, focus servo controller 150 uses expected focal plane shift 811 and x,y position 813 for the laser beam to determine a servo control signal for focus servo 115. Thus, at step 708, focus servo controller 150 is adjusting the focus to ensure that the focal points at all x,y positions are in a common focal plane and to compensate for expected focal plane shift 811 due to heating of the optics.
At step 710, focus servo controller 150 sends a servo control signal to focus servo 115, which controls the position of servo driven expansion lens 114. Focus servo 115 then moves expansion lens 114, thereby altering at least one feature of the optics based on the expected focal plane shift, so as to maintain the focal point substantially on the piece of working material. At the same time, x-y position controller 152 sends a control signal to galvo servos 816, which move mirrors 120 and 122 to position the laser beam at x,y position 813. At the same time, focus servo controller moves servo-driven lens 114 to ensure that the common focal plane is located substantially at the working material. Thus, while galvo servos 816 are able to direct the laser beam in two dimensions (x,y), focus servo 115 moves servo-driven lens 114 to different positions to change the position of the focal point of the laser beam in a third dimension (z), orthogonal to the x,y dimensions, wherein for different (x,y) positions for the laser beam, the servo-driven lens is moved to different positions so that the position of the focal point of the laser beam in the third dimension (z) is the same for all (x,y) positions.
After step 710, the process returns to step 704 to wait for the next focal plane adjustment time and when the next focal plane adjustment time arrives, steps 705, 706, 707, 708 and 710 are repeated for a new current power level resulting in a new expected focal plane shift 811 and a new focus servo control signal. Thus, focal plane shift compensator 802 continues to provide new expected focal plane shifts 811 at each new focal plane adjustment time to thereby continuously adjust the focal plane to compensate for laser heating of the optics.
An example of a computing device 10 that can be used to implement test controller 600, timer 604, controller 102, control electronics/focal shift compensator 802, x-y position servo controller 152, focus servo controller 150 and laser controller 103 in the various embodiments is shown in the block diagram of
Computing device 10 of
Embodiments of the present invention can be applied in the context of computer systems other than computing device 10. Other appropriate computer systems include handheld devices, multi-processor systems, various consumer electronic devices, mainframe computers, and the like. Those skilled in the art will also appreciate that embodiments can also be applied within computer systems wherein tasks are performed by remote processing devices that are linked through a communications network (e.g., communication utilizing Internet or web-based software systems). For example, program modules may be located in either local or remote memory storage devices or simultaneously in both local and remote memory storage devices. Similarly, any storage of data associated with embodiments of the present invention may be accomplished utilizing either local or remote storage devices, or simultaneously utilizing both local and remote storage devices.
Computing device 10 further includes a hard disc drive 24, a solid state memory 25, and an optical disc drive 30. Optical disc drive 30 can illustratively be utilized for reading data from (or writing data to) optical media, such as a CD-ROM disc 32. Hard disc drive 24 and optical disc drive 30 are connected to the system bus 16 by a hard disc drive interface 32 and an optical disc drive interface 36, respectively. The drives, solid state memory and external memory devices and their associated computer-readable media provide nonvolatile storage media for computing device 10 on which computer-executable instructions and computer-readable data structures may be stored. Other types of media that are readable by a computer may also be used in the exemplary operation environment.
A number of program modules may be stored in the drives, solid state memory 25 and RAM 20, including an operating system 38, one or more application programs 40, other program modules 42 and program data 44. For example, application programs 40 can include instructions for implementing any of the modules described above such as test controller 600, timer 604, controller 102, curve generator 800, and focal plane shift identifier 808. Program data can include any data used in the steps described above including laser power level 602, time/focal plane shift curves 612, production instructions 812, laser power level 804, laser “on” time 810, time/focal plane shift curve 806, expected focal plane shift 811 and x,y positions 813.
Input devices including a keyboard 63 and a mouse 65 are connected to system bus 16 through an Input/Output interface 46 that is coupled to system bus 16. Display 224 is connected to the system bus 16 through a video adapter 50 and provides graphical images to users. Other peripheral output devices (e.g., speakers or printers) could also be included but have not been illustrated. In accordance with some embodiments, display 224 comprises a touch screen that both displays input and provides locations on the screen where the user is contacting the screen.
Computing device 10 may operate in a network environment utilizing connections to one or more remote computers. The remote computer may be a server, a router, a peer device, or other common network node. The remote computer may include many or all of the features and elements described in relation to computing device 10. The network connections to device 10 can include a local area network (LAN) and a wide area network (WAN), for example. Such network environments are commonplace in the art. Computing device 10 is connected to the LAN through a network interface 60. Computing device 10 is also connected to the WAN 58 through a modem, which may be internal or external.
In a networked environment, program modules depicted relative to computing device 10, or portions thereof, may be stored in the remote memory storage device of a remote computer. For example, application programs may be stored utilizing such remote memory storage devices. In addition, data associated with an application program may illustratively be stored within remote memory storage devices. It will be appreciated that the network connections shown in
Device 10 includes a PCI Card 91, which is connected to galvo servos 816, focus servo 115, and laser 104. PCI Card 91 includes a digital signal processor that executes instructions to perform tasks assigned to x-y position servo controller 152, focus servo controller 150 and laser controller 603. In some embodiments, the functions assigned to curve generator 800 and focal plane shift identifier 808 are also executed by the digital signal processor in PCI Card 91. In such embodiments, laser power level 804, laser “on” time 810, time/focal plane shift curves 612, time/focal plane shift curve 806, expected focal plane shift 811 and x,y positions 813 are stored in storage electronics/memory on PCI Card 91. In still further embodiments, controller 102 is implemented by the processor in PCI Card 91 and production instructions are stored in storage electronics/memory on PCI Card 91.
Although elements have been shown or described as separate embodiments above, portions of each embodiment may be combined with all or part of other embodiments described above.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
The present application is based on and claims the benefit of U.S. provisional patent application Ser. No. 62/192,910, filed Jul. 15, 2015 the content of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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62192910 | Jul 2015 | US |