Machining head for a laser machining device
11219967 · 2022-01-11
Assignee
Inventors
Cpc classification
G01B9/02044
PHYSICS
B23K26/046
PERFORMING OPERATIONS; TRANSPORTING
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
G01B9/02063
PHYSICS
B23K26/0665
PERFORMING OPERATIONS; TRANSPORTING
G01B9/02091
PHYSICS
G01B9/02028
PHYSICS
B23K26/048
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/04
PERFORMING OPERATIONS; TRANSPORTING
B23K26/06
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A processing head for a laser processing device adapted for processing a workpiece using laser radiation has: adjustable focusing optics to focus laser radiation in a focal spot having an adjustable distance from the processing head; an optical coherence tomograph to measure a distance between the processing head and the workpiece by measuring an optical interference between measuring light reflected by the workpiece and measuring light not reflected by the workpiece; a path length modulator that can change, synchronously with and dependent on a change of the focal spot distance from the processing head, an optical path length in an optical path along which measuring light propagates; a scanning device, which deflects the laser radiation in different directions; and a control device, which i) controls a focal length of the focusing optics in such a way that the focal spot is situated at a desired location on the workpiece, ii) receives, from the coherence tomograph, information representing the distance between the processing head and the workpiece, and iii) uses information received from the coherence tomograph for a continuous correction of a positioning of the focal spot on the workpiece.
Claims
1. A processing head for a laser processing device adapted for the processing of a workpiece using laser radiation, wherein the processing head comprises; adjustable focusing optics configured to focus the laser radiation in a focal spot having an adjustable distance from the processing head; an optical coherence tomograph configured to measure a distance between the processing head and the workpiece by measuring an optical interference between a first measuring light, which was reflected by the workpiece, and a second measuring light, which was not reflected by the workpiece; a path length modulator that is configured to change, synchronously with and dependent on a change of the distance of the focal spot from the processing head, an optical path length in an optical path along which the second measuring light propagates; a scanner that is arranged in the optical path of the first measuring light; a scanning device, which is configured to deflect the laser radiation in different directions; and a control device, which is configured to i) control a focal length of the focusing optics in such a way that the focal spot is situated at a desired location on the workpiece, ii) receive, from the coherence tomograph, information representing the distance between the processing head and the workpiece, and iii) use the information received from the coherence tomograph for a continuous correction of a positioning of the focal spot on the workpiece, wherein the scanner is arranged exclusively in the optical path of the first measuring light.
2. The processing head of claim 1, wherein, when the focal length of the focusing optics changes by Δd, the path length modulator changes the optical path length in the optical path by 2Δd.
3. The processing head of claim 1, wherein the optical coherence tomograph is an FD-OCT.
4. The processing head of claim 1, wherein the first measuring light passes through at least one movable part of the focusing optics, and wherein the focal length of the focusing optics depends on a position of the movable part.
5. The processing head of claim 4, wherein the first measuring light, after passing through the focusing optics, is always focused in the same focal plane in which the focal spot of the laser radiation is situated.
6. A processing head for a laser processing device adapted for the processing of a workpiece using laser radiation, wherein the processing head comprises; adjustable focusing optics configured to focus the laser radiation in a focal spot having an adjustable distance from the processing head; an optical coherence tomograph configured to measure a distance between the processing head and the workpiece by measuring an optical interference between a first measuring light, which was reflected by the workpiece, and a second measuring light, which was not reflected by the workpiece; a path length modulator that is configured to change, synchronously with and dependent on a change of the distance of the focal spot from the processing head, an optical path length in an optical path along which the second measuring light propagates; a scanning device, which is configured to deflect the laser radiation in different directions; and a control device, which is configured to i) control a focal length of the focusing optics in such a way that the focal spot is situated at a desired location on the workpiece, ii) receive, from the coherence tomograph, information representing the distance between the processing head and the workpiece, and iii) use the information received from the coherence tomograph for a continuous correction of a positioning of the focal spot on the workpiece, wherein, at any given time, regions of the workpiece that reflect the first measuring light are not exposed to the laser radiation.
7. The processing head of claim 6, comprising a scanner that is arranged exclusively in the optical path of the first measuring light.
8. The processing head of claim 6, wherein, when the focal length of the focusing optics changes by Δd, the path length modulator changes the optical path length in the optical path by 2Δd.
9. The processing head of claim 6, wherein the optical coherence tomograph is an FD-OCT.
10. The processing head of claim 6, wherein the first measuring light passes through at least one movable part of the focusing optics, and wherein the focal length of the focusing optics depends on a position of the movable part.
11. The processing head of claim 10, wherein the first measuring light, after passing through the focusing optics, is always focused in the same focal plane in which the focal spot of the laser radiation is situated.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Further features and advantages of the invention will become apparent from the following description of the exemplary embodiments with the aid of the drawings, in which:
(2)
(3)
(4)
(5)
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(9)
(10)
(11)
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(13)
DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS
1. Structure of the Laser Processing Device
(14)
(15) The laser processing device 10 also includes a laser radiation source 18 which is formed in the illustrated exemplary embodiment as a disc laser or fibre laser. Laser radiation 30 generated by the laser radiation source 18 is supplied via an optical fibre 20 to the processing head 14 and focused by the latter in a focal spot 22.
(16) The laser processing device 10 is provided for a remote laser processing of workpieces. The distance between the focal spot 22 and the processing head 14 is therefore about 30 cm to 100 cm. As will be explained below with reference to
(17) In the exemplary embodiment illustrated in
(18)
(19) In the beam path downstream of the focusing optics 34, the scanning device, already mentioned and designated by 44, is arranged. This device includes one or more galvanically suspended mirrors, with which the laser radiation 30 can be deflected in different directions, as indicated by a dashed beam path 46. Since such scanning devices are known as such in the prior art, a more detailed explanation of the structure is omitted.
(20) Through the interaction of the scanning device 44 with the moving device 40 of the focusing optics 34, the focal spot 22 can be positioned at any desired locations on the steel plates 24a, 24b within a larger volume.
(21) In order to be able to measure the distance of the workpiece from the processing head 14, the latter includes the optical coherence tomograph already mentioned, which is designated as a whole by 48 in
(22) In the object arm 58 the measuring light is firstly widened by telescopic optics 62 and then coupled into the beam path of the laser radiation 30 by the first beam splitter 32. The telescopic optics 62 comprise, in the exemplary embodiment illustrated, a diverging lens 64 and a converging lens 66. Arranged between the lenses 64, 66 is an adjustable glass path adapter 68, consisting of two wedge prisms 70, 72 which are displaceable relative to one another and between which an index-matched gel is situated. Through displacement of the wedge prisms 70, 72, the axial length of the glass path adapter 68 can be continuously adjusted. In this way, it is possible to integrate the optical coherence tomograph 48 also into existing processing heads 14 and, with the aid of the glass path adapter 68, always set equal path lengths in dispersing glasses.
(23) Situated at the end of the reference arm is a path length modulator 74 consisting, in the exemplary embodiment illustrated, of a plane mirror 76 which is movable in the axial direction with the aid of a linear drive 78. In this way, the optical path length in the reference arm 60 can be continuously adjusted.
(24) The coherence tomograph 48 further comprises a spectrally resolving light sensor 80 which detects the interference of measuring light, which has been reflected by the steel plates 24a, 24b, with measuring light which has travelled a similar optical distance in the reference arm.
(25) The coherence tomograph 48 operates in the frequency domain (FD-OCT). As a result, for a given optical path length in the reference arm 60, a measuring range in the axial direction of about 8 mm is possible. Since, apart from the path length modulator 74 which has yet to be explained in more detail, such coherence tomographs 48 are known in the prior art, the function will not be explained again in detail here. Fundamentally, coherence tomographs with optical circulators, as described in DE 10 2010 016 862 B3 of the applicant, are also suitable.
(26)
(27) If this lengthening goes beyond about 8 mm, the measuring range of the coherence tomograph 48 would thereby be exceeded. Therefore, the plane mirror 76 in the path length modulator 74 is shifted synchronously with the displacement of the first lens 36 by the same amount by which the focal length was lengthened. In this way, the optical path lengths in the reference arm 60 and in the object arm 58 correspond again, so that the entire measuring range of the coherence tomograph 48 of about 8 mm is usable.
(28) In order to synchronise the displacements of the lens 36 of the focusing optics with the plane mirror 76 of the path length modulator 74, the moving device 40 and the path length modulator 74 are connected to a common regulating and control device 82 via signal lines. The regulating and control device 82 also controls the scanning device 44. It is supplied with measuring signals of the light sensor 80 which, after evaluation, provide the optical path length difference in the object arm and the reference arm 58 and 60, respectively. Since the optical path length in the reference arm is known (the axial position of the plane mirror 76 should therefore be detected exactly by an encoder), the regulating and control device 82 can control the moving device 40 of the focusing optics 34 and also the scanning device 44 such that the focal spot is positioned exactly at the desired location on the steel plates 24a, 24b. This positioning is preferably carried out by means of a regulating loop, in which the measured values provided by the coherence tomograph 48 are used for continuous correction of the positioning of the focal spot 22.
2. Path Length Modulators
(29) For workpieces with a large depth profile, the focal spot 22 must be shifted very rapidly by greater distances in the axial direction. For this there suffice short moving distances of the first lens 36 of the focusing optics 34, which are easy to accomplish in spite of the relatively large mass of the first lens 36. The axial shifting of the focal spot 22 can in this case be greater, for example, by an order of magnitude than the moving distance of the first lens 36.
(30) The situation is different, however, in the path length modulator 74. In the exemplary embodiment shown in
(31) a) Beam Folding
(32) In the exemplary embodiment of the path length modulator shown in
(33) A shifting of the 90° prism 84 in the axial direction, as indicated in
(34) Especially when the measuring light 52 is guided in the coherence tomograph 48 not in free space, but in optical fibres, the variant of a path length modulator 74 shown in
(35)
(36) This structure too can be combined with the principle shown in
(37)
(38) If the two 90° prisms 84, 94 are arranged at an azimuthal angle of 60° to one another, as illustrated in a representation based on
(39) b) Optical Switches
(40) In the second group of path length modulators, the optical path length in the reference arm 60 is not continuous, but changes in discrete steps. For this purpose, the path length modulator 74 has a multiplicity of optical channels metal-coated on one side and of different length and an optical switch, with which the measuring light 52 can be sequentially coupled into respectively one of the optical channels.
(41) In the exemplary embodiment shown in
(42) Each of the total of 8 optical fibres 96-1 to 96-8 has a different length. The optical switch is formed as a rotatably mounted tilting mirror 100. Measuring light 52 entering the reference arm 60 is coupled by the tilting mirror 100 into an antireflection-coated end surface of one of the optical fibres; in
(43) Through pivoting of the tilting mirror 100, the measuring light 52 can be coupled into any of the eight optical fibres 96-1 to 96-8. In each optical fibre 96-1 to 96-8, the measuring light 52 travels a different optical distance.
(44)
(45) The optical fibres 96 have the advantage that they can be rolled up or otherwise space-savingly arranged in the processing head 14. As a result, optical path length differences of practically any size can be produced.
(46) In the exemplary embodiment of a path length modulator 74 shown in
(47) The plane mirrors 102 have different distances from the tilting mirror 100 and are so oriented that incident measuring light 52 is always reflected back on itself. As
(48) In order to make the arrangement less sensitive to adjustment tolerances, a converging lens 103 is respectively arranged in the beam path between the tilting mirror 100 and the plane mirrors 102-1 to 102-8. This lens focuses the incident measuring light 52 to a point on the respective plane mirror 102-1 to 102-8.
(49) If the measuring light 52 emerges from an optical fibre, it can be collimated with the aid of a converging lens before impinging on the tilting mirror 100, as shown in
3. Further Exemplary Embodiments
(50)
(51) An approximately circular scanning of the surface of the workpiece 24 to be processed is not suitable for regulation of the focal spot distance, but also allows a detection of the seam following the laser processing. Processing errors can thereby be detected early. The circular shape here ensures an independence from the processing direction. The circular radius here can be in the order of about 5 mm. Then there is still enough time, depending on the measuring results, to intervene in the processing procedure.
(52)
(53) The measuring light guided in the measuring arm 58 of the coherence tomograph 48 likewise exits from an optical fibre 112 and therefore likewise passes through a converging lens 114 before it is coupled via a deflecting mirror 116 into the focusing optics 34.
(54) In order that the focal spot 108 of the measuring light 52 is always superimposed on the focal spot 22 of laser radiation, the converging lens 114 must also be shifted in the beam path of the measuring light 52, since the linearly-movably arranged converging first lens 36′ is traversed only by the laser radiation 30. In the exemplary embodiment illustrated, the converging lens 114 is therefore moved by the same moving device 40 as the converging first lens 36′. It is even possible to arrange the two lenses 36′, 114 on the same moving carriage, so that they move synchronously and at the same speed.
4. Planning of the Processing Procedure
(55) When planning the processing procedure it should be taken into account that the measuring range of the coherence tomograph 48 consists of two halves, which are interrupted by a dead zone in the middle. The reason for this is that the measuring range of FD-OCTs does not begin with a path difference of 0, but where a significant modulation can already be seen. The upper boundary of the measuring range, however, is reached on arriving at the undersampling.
(56) Without any special measures, it is indistinguishable whether the reference arm 60 or the object arm 58 is longer, i.e. whether the measured optical path length difference is negative or positive. This is illustrated by
(57) If the workpieces can be positioned with the precision of the measuring range of the coherence tomograph (about 8 mm), then the processing procedure can be set, for example, so that the optical path length in the reference arm 60 is initially set by the path length modulator 74 so that the distance on travelling along the processing line remains safely in one of the two OCT measuring subranges “+” or “−” shown in
(58) In the case of heavily stepped objects, the measuring range can be started so that one of the two steps remains in the “−” OCT measuring subrange and the other step remains in the “+” OCT measuring subrange. The transition between upper and lower step must then be recognised from the context, e.g. from the phase position of the measuring signal supplied by a circular scanner and a jump in the OCT measuring value. At this transition the sign of the OCT measuring value must be flipped.