LASER BEAM POSITIONING SYSTEM, LASER PROCESSING DEVICE AND CONTROL METHOD
20210031299 ยท 2021-02-04
Inventors
Cpc classification
G05B19/402
PHYSICS
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
B23K26/043
PERFORMING OPERATIONS; TRANSPORTING
G02B26/101
PHYSICS
International classification
B23K26/04
PERFORMING OPERATIONS; TRANSPORTING
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method is provided of controlling a laser processing device with at least one laser. The method includes setting an optical path of the laser processing device by at least one rotatable mirror; a first triggering of the laser at a first point in time so as to generate a first laser spot; continuously adjusting, the optical path of the laser processing device; and a second triggering of the laser at a second point in time so as to generate a second laser spot. The method also includes, before the second triggering: determining the second point in time so that the position of the second laser spot has a desired distance, along the path, to the position of the first laser spot.
Claims
1. A method of controlling a laser processing device having at least one laser, comprising: setting an optical path of the laser processing device by at least one deflection element, including at least one rotatable mirror, so that a path point which can be generated by a laser beam following the optical path lies on a desired path on or in an object; a first triggering of the laser at a first point in time so as to generate a first laser spot; adjusting, in particular continuously adjusting, the optical path of the laser processing device by the at least one rotatable mirror, so that a path point which can be generated by the laser beam following the optical path lies on the desired path; a second triggering of the laser at a second point in time so as to generate a second laser spot; wherein the method comprises the following step before the second triggering: determining the second point in time on the basis of at least one of a target position, a first or a higher time derivative thereof, and a first or a higher time derivative of an actual position of the path point of the optical path along the desired path, so that a position of the second laser spot has a desired distance, along the desired path, to a position of the first laser spot.
2. The method according to claim 1, wherein the second point in time is a point in time at which the path point of the optical path has reached or exceeded a desired minimum distance along the desired path from the position of the first laser spot.
3. The method according to claim 1, further comprising: (a) at least a third triggering of the laser; and (b) ensuring that, per length of the desired path, an energy which is transmitted onto the object by the laser beam substantially corresponds to a desired distribution.
4. The method according to claim 3, wherein the desired distribution specifies that an energy per length of the desired path is substantially constant.
5. The method according to claim 3, wherein the desired distribution specifies that an energy per length of the desired path is lower in curves of the desired path than on substantially straight sections of the desired path.
6. The method according to claim 3, wherein a distance between successive laser spots is varied so that an energy per length of the desired path substantially corresponds to the desired distribution.
7. The method according to claim 3, wherein an energy which is transmitted onto the object by the laser beam in order to generate a laser spot is varied for different laser spots so that an energy per length of the desired path substantially corresponds to the desired distribution.
8. The method according to claim 3, wherein the laser spots have a size, and the desired distribution specifies that successive laser spots do not overlap.
9. The method according to claim 2, wherein the second point in time is determined on the basis of the first or the higher time derivative of the target position or the actual position as follows: repeating of the following steps: (a) integrating the first or the higher time derivative of the target position or the actual position over a time interval in order to determine a first distance along the desired path; and (b) comparing the first distance with the desired minimum distance along the desired path, until the first distance corresponds to, or exceeds, a desired minimum distance along the desired path; and determining the second point in time from a sum of the time intervals.
10. The method according to claim 9, wherein further points in time which are subsequent to the second point in time are determined according to the determination of the second point in time, however while additionally taking into account to what extent the desired minimum distance was exceeded during a course of the determination of the preceding point in time.
11. The method according to claim 9, wherein further points in time which are subsequent to the second point in time are determined according to the determination of the second point in time, without taking into account to what extent the desired minimum distance was exceeded during the course of the determination of the preceding point in time.
12. The method according to claim 2, wherein the second point in time is determined on the basis of the target position as follows: for a given point in time, determining whether the target position which is associated with the given point in time corresponds to a distance along the desired path that is equal to the desired minimum distance or has exceeded the desired minimum distance along the desired path; if yes, using the given point in time as the second point in time; if no, adding a time interval to the given point in time; and repeating the preceding steps.
13. A computer program product comprising a program code which is stored on a computer-readable medium for carrying out a method comprising: setting an optical path of the laser processing device by at least one deflection element, including at least one rotatable mirror, so that a path point which can be generated by a laser beam following the optical path lies on a desired path on or in an object; a first triggering of the laser at a first point in time so as to generate a first laser spot; adjusting, in particular continuously adjusting, the optical path of the laser processing device by the at least one rotatable mirror, so that a path point which can be generated by the laser beam following the optical path lies on the desired path; a second triggering of the laser at a second point in time so as to generate a second laser spot; wherein the method comprises the following step before the second triggering: determining the second point in time on the basis of at least one of a target position, a first or a higher time derivative thereof, and a first or a higher time derivative of an actual position of the path point of the optical path along the desired path, so that a position of the second laser spot has a desired distance, along the desired path, to a position of the first laser spot.
14. (canceled)
15. A laser beam positioning system for controlling a laser processing device, the laser beam positioning system comprising: at least one deflection element, including at least one rotatable mirror, means for setting or continuously adjusting, the at least one rotatable mirror, in order to set or adjust an optical path of the laser beam positioning system in such a way that a path point which can be generated by a laser beam following the optical path lies on a desired path on or in an object; means for triggering, at first and second points in time, a laser to be used with the laser beam positioning system in order to generate a first and a second laser spot; and means for determining the second point in time on the basis of at least one of a target position, a first or a higher time derivative thereof, and a first or a higher time derivative of an actual position of the path point of the optical path along the desired path, so that a position of the second laser spot has a desired distance, along the desired path, to a position of the first laser spot.
16. A laser processing device comprising: the laser beam positioning system according to claim 15; and a laser.
17. The laser beam positioning system of claim 15, wherein the laser beam positioning system performs a method comprising: setting an optical path of the laser processing device by at least one deflection element, including at least one rotatable mirror, so that a path point which can be generated by a laser beam following the optical path lies on a desired path on or in an object; a first triggering of the laser at a first point in time so as to generate a first laser spot; adjusting, in particular continuously adjusting, the optical path of the laser processing device by the at least one rotatable mirror, so that a path point which can be generated by the laser beam following the optical path lies on the desired path; a second triggering of the laser at a second point in time so as to generate a second laser spot; wherein the method comprises the following step before the second triggering: determining the second point in time on the basis of at least one of a target position, a first or a higher time derivative thereof, and a first or a higher time derivative of an actual position of the path point of the optical path along the desired path, so that a position of the second laser spot has a desired distance, along the desired path, to a position of the first laser spot.
18. The method according to claim 3, wherein the laser spots have a size, and the desired distribution specifies that successive laser spots overlap only up to a maximum specified extent.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, explain the one or more embodiments of the invention.
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
DETAILED DESCRIPTION
[0052] The laser processing device 10 shown in
[0053] The laser beam 3 then hits a rotatable mirror 4a, which deflects the laser beam 3. After having been deflected by the rotatable mirror 4a, the laser beam 3 hits another rotatable deflection mirror 4, which deflects it in the direction of an object 6.
[0054] The rotatable mirrors 4, 4a are part of a laser beam positioning system 1, which can also include, among other things, an objective 30, as is in principle known from the state of the art. In the example shown, the deflection mirrors 4, 4a are arranged in such a way that they can rotate around axes that include a 90 angle. Other angles would also be conceivable, but choosing a 90 angle can make it easier to calculate the position of the focal point from the axis positions of the mirrors. The rotatable deflection mirrors 4, 4a can be rotated by galvanometer drives, for example.
[0055] The laser beam deflected by the mirrors 4, 4a then hits an object 6. In
[0056] In
[0057] When the laser 2 is triggered, the laser 2 or the laser beam 3, 5 generates a laser spot at the position of the focal point 8. If the laser 2 is triggered several times in succession, a series of laser spots is generated in or on the object 6. For the sake of simplicity, in the following, the reference sign 8 is also used for the laser spot(s).
[0058] An optical path for the laser 2 is defined by the deflection mirrors 4, 4a and, if present, the focusing device 4b. In the following, the reference sign 40 is used for the optical path, although this is not shown in the drawings. The optical path 40 corresponds to a line along which the laser beam 3, 5, starting at the laser 2, would propagate if the laser 2 was triggered. The optical path is therefore also defined at such times when the laser 2 is not triggered. Likewise, the optical path 40 can be considered as being defined if the laser 2 is not present because the optical path is defined by the deflection mirrors 4, 4a and, if present, the focusing device 4b.
[0059] If the mirrors 4, 4a and, if applicable, the focusing device 4b are adjusted, the optical path 40 changes and thus also the position of the focal point 8. The optical path 40 or the focal point 8 thus describes a path that lies at least partially, in particular completely, in or on the object 6. Individual path points are located along this path, which are described below and for which the reference sign 8 is also used.
[0060] In the example embodiment shown, the laser beam positioning system 1 comprises a control system 20. By this control system, in particular the deflection mirrors 4 or 4a and the focusing device 4b can be controlled and/or their (axis) positions can be determined. As shown in
[0061] The invention is not limited to the implementation shown in
[0062] Regardless of the particular implementation, the mirrors 4, 4a and the control system 20, if applicable together with other optical elements, can be regarded as a laser beam positioning system. It is noted again that the laser 2 is not, or at least not necessarily, a part of this system. The laser beam positioning system 1 can be provided separately, for use with a laser 2. The combination of the laser beam positioning system 1 and the laser 2 can be regarded as a laser processing device 10.
[0063] According to a variant of the arrangement shown in
[0064] As shown in
[0065] As a further variant, it is possible to use other deflection elements instead of deflection mirrors 4, 4a. In particular, optical waveguide or prisms could be considered for this purpose. It would also be possible to combine different types of deflection elements with each other, for example a mirror and an optical waveguide. However, at least one of the deflection elements must in this embodiment be such that it can be adjusted/modified with respect to its position, orientation or shape (in particular in the case of an optical fiber), so that the optical path of the laser processing device can be adjusted accordingly.
[0066]
[0067] Here, the deflection mirror 4 is representative for one or more deflection elements.
[0068] The laser beam which is deflected by the deflection mirror 4 again carries the reference sign 5. Where the laser beam 5 hits the object 6, a laser spot 8 (at focal point 8) is generated. The optical path of the laser processing device 10 is adjusted by suitable control of the deflection mirror 4 in such a way that it describes a path 7 on the object 6.
[0069] A continuous path 7 is generated through continuous adjustment of the at least one deflection mirror 4, as shown in
[0070] It will now be described how the points in time at which the laser 2 is triggered are determined. In this context the centers of the laser spots are preferably meant, when reference is made to the position of the laser spots or the distance between two adjacent laser spots.
[0071] Three example embodiments of the present invention will now be described. In all of these it is assumed that the deflection elements 4 are set or adjusted in such a way that a path point 8 which can be generated by a laser beam 3, 5 following the optical path 40 lies on a desired path 7 on or in the object 6.
Example Embodiment 1: Target Speed
[0072] The deflection mirrors 4 are controlled in such a way that the optical path describes the desired path 7. In particular, if position controllers without tracking errors are used for the deflection mirrors 4, the controlling of the deflection mirrors 4 can be used to determine the position which the optical path will assume on the desired path 7 at different points in time. This is therefore not a (measured) actual position of either the deflection mirrors 4 or of the optical path 40 along the desired path. Rather, the target position of the optical path on the desired path can be determined from the controlling, in particular even before the position controllers of the deflection mirrors 4 are activated. In a manner known in principle, the target speed V.sub.soll along the path can also be determined from this. This target speed can be represented by a scalar because the direction of movement is given anyway by the specification of the desired path.
[0073] The method according to this example embodiment envisages that the target speed is integrated in small time intervals. The integration steps can be 10 ns, for example. In any case it is desirable that the integration time interval is much shorter than the expected time interval between the trigger pulses.
[0074] The integration of the target speed along the path is illustrated in
[0075] Depending on the application, a certain desired (length-wise) distance along the path between two successive laser spots which are to be generated would be specified. This distance is marked with A. The target speed along the path is now integrated (in particular numerically) over a first time interval t1 in order to determine a first distance A1 therefrom. This distance A1 is compared with the desired distance A. If the distance A1 has not yet reached the desired distance A, the method is continued or repeated, i.e. the integration of the target speed along the path is continued in a second time interval t2 and the result is again compared with the desired distance A. The time integration intervals t1 to to can all have the same or a different length. The integration is continued until the distance along the path determined by the integration has reached or exceeded the desired distance A. In
[0076] In many cases the distance along the path determined by the integration will not exactly reach the desired distance A, butdepending on the choice of the integration intervalwill exceed it slightly. As soon as the distance along the path determined by the integration has reached or exceeded the desired distance A (A7), the point in time for the triggering of the laser 2, or the time interval between a first triggering of the laser 2 and a subsequent, second triggering of the laser 2, can be determined by summing up the time intervals t1 to t7 used in the course of the integration. The two laser spots generated by the first and the second triggering will then have the desired distance A or a distance A (A7 in
[0077] When the method is continued in order to determine the trigger point in time for a third laser spot, the distance difference dA can be taken into account. Thus, the integration or the summation can start with an initial value which is different from zero, whereby this initial value corresponds to the distance difference dA. As a result, the desired distance A is reached faster than would be the case purely on the basis of an integration of the target speed along the path over the integration time intervals. This in turn means that the time interval until the third trigger point in time of the laser 2 and thus also the (length-wise) distance along the path between the second and the third laser spots is reduced slightly. In particular, the length-wise distance between the second and the third laser spots may then possibly be (slightly) smaller than the desired distance A. It is to be expected that the deviations of the distances from the desired distance A will balance each other out on average, so that the average distance approximately corresponds to the desired distance.
[0078] The method can be continued in a corresponding manner for further trigger points in time or laser spots.
[0079] This example embodiment also provides for the case that the method can be adapted accordingly if the desired distances along the path between two successive laser spots are not constant.
Example Embodiment 2: Actual Speed
[0080] The method according to the second example embodiment is very similar to that of the first one. The main difference is that the integration is not based on the target speed, but on the actual speed V.sub.Ist. The actual speed along the path can be determined by measurement of the current axis positions of the deflection mirrors 4.
Variant: Higher Time Derivatives
[0081] As a variant to the example embodiments 1 and 2, instead of the target speed or the actual speed along the path, higher time derivatives of the target position or the actual position along the path can also be used for the integration. In such a case the integration would accordingly have to be carried out several times, so that the result of the integration corresponds to the distance along the path.
Example Embodiment 3: Target Position
[0082] The third example embodiment is similar to the first in that, again, target values which result from the controlling of the deflection elements 4 are used, as opposed to (measured) actual values. However, in the third example embodiment, the target position is used instead of the target speed. In this case there is no need to carry out any integration. Instead, after a sufficiently small time interval, which preferably is again significantly smaller than the temporal pulse interval to be expected, a check takes place as to whether the target position along the path corresponds to a distance (with respect to a preceding laser spot) along the path that corresponds to the desired distance of the laser spots or has exceeded the desired distance along the path. As soon as this is the case, the trigger point in time to be used can be determined from this. Otherwise, a time interval is added and the comparison is carried out again.
[0083] As in the first and second example embodiment, in the course of the third example embodiment it can also be taken into account to what extent the desired distance between two laser spots has been exceeded, i.e. a distance difference dA can again be determined. This in turn means that, when the subsequent trigger point in time is being determined, the desired distance A will be reached faster than would be the case purely on the basis of the target positions along the path. As a result, on average, the actual distance between successive laser spots can again converge towards the desired distances between these laser spots.
Variants
[0084] In a first variant to the example embodiments described above, it would be possible to determine successive trigger points in time without taking into account to what extent a preceding laser spot has exceeded the desired distance. This can simplify the computational complexity, because no carry from the calculation of a preceding trigger point in time has to be taken into account as part of the determination of a subsequent trigger point in time. On each occasion the calculation starts at zero, so to speak. However, it is to be expected that the distances determined between the laser spots will be (slightly) larger than the desired distances between these.
[0085] According to a second variant to the first and second example embodiments, the target or actual velocity values used for the integration are interpolated, in particular using a linear interpolation. In this context, a time interval between two such interpolation points in time can be significantly longer than the duration of one of the integration intervals. The points of time between which the interpolation takes place can be given by a clock frequency of a control card of the laser beam positioning system. In one embodiment, this clock frequency can for example be a few microseconds, for example 10 s, while an integration interval can for example be a few nanoseconds, for example 5 to 20 ns. For each integration time interval, a velocity value can thus be approximated in a relatively simple way. The inventors have appreciated that such an interpolation usually requires considerably less computing capacity than, for example, an analytical determination of the velocity for each integration interval. At least with a suitable choice of the points in time between which the interpolation takes place, this interpolation method provides results with completely sufficient accuracy for most applications.
Further Explanations/Example Embodiments
[0086] In many applications, it will be desirable to generate hundreds of laser spots, possibly thousands of laser spots or far more. It may be desired that the distances between successive laser spots have a desired distribution, for example that the distances are substantially constant. It has already been mentioned that a laser which is triggered with a constant clock frequency generally will not (or not necessarily) generate equidistant laser spots. This is because the speed of the optical path along the path needs to be taken into account. This is explained with reference to
[0087]
[0088] Example embodiments of the invention take into account the profile of the spot velocity when determining the trigger points in time, as shown in
[0089] In further example embodiments, however, it may also be desired that the energy input per length of the path corresponds to a desired distribution, for example, that it remains constant. The energy input per length of the path can be varied according to example embodiments of the present invention by suitable selection of the distance between successive laser spots or by suitable selection of the energy per laser spot (pulse energy). It is also possible to vary both the distance between successive laser spots and the energy per laser spot in order to influence the energy input per length of the path.
[0090] When choosing the distance between successive laser spots and/or the energy per laser spot, the fact may possibly also be taken into account that the shape of the laser spots varies in dependence upon the position in the processing area.
[0091]
[0092] The distance between the first and second laser spots along the path 7 is marked A12, and the distance along the path between the second and third laser spots is marked A23. The path 7 is curved, whereby the curvature in
[0093] Alternatively, under certain circumstances it would be possible to adjust the extent of the laser spots accordingly, i.e. smaller on curves than on substantially straight sections, or the energy per laser spot (pulse energy) could be adjusted accordingly so that, despite the overlapping of the laser spots, the energy input per length of the path corresponds to the desired distribution, for example that it remains constant.
[0094] The inventors envisage the following as a specific implementation of an example embodiment. Based on the target path and the dynamic limits (max. speed, max. acceleration, max. jerk) of the system to be used, a navigable trajectory is pre-calculated in discrete steps (for example 10 s) for all axes. The output for the axes can be shifted in time, in order to compensate for propagation time differences etc. Position controllers which are free of tracking errors are used for all axes, so that the deviation between the target path and the actual path can be neglected. The focus velocity (or spot velocity or speed of the optical path along the path) is calculated according to the same clock (in this example in 10 s cycles). The laser power and the spot distance (distance between the laser spots) can be changed in 10 s cycles if necessary. The laser power can be pre-calculated in dependence upon the speed, the laser frequency, the position, the angle of incidence and the path curvature etc. Alternatively, these values can also be included as a correction term in a pseudo speed. A minimum laser frequency can also be taken into account in the pseudo speed.
[0095] In order to generate the laser trigger signal, the velocity signal is linearly interpolated and integrated within the 10 s interval, whereby the summing up is carried out e.g. according to a clock of a few ns. When the desired spot distance is exceeded, a defined pulse is triggered and the counter reading is reduced by the spot distance.
Summarized Description of a Method Flow According to the Invention
[0096]
[0097] In a next step 120, the laser 2 is triggered at a first point in time in order to generate a first laser spot on the path 7.
[0098] The optical path is adjusted in a next step 130. It should be noted here that the initial setting (110) and the subsequent adjustment (130) can, in many embodiments, be regarded as a continuous process.
[0099] In a further step 140, a second point in time is determined at which the laser 2 is to be triggered for a second time.
[0100] In a next step 150, the laser 2 is triggered at the second point in time previously determined, in order to generate a second laser spot on the path 7.
[0101] In a further step 160 a check is made as to whether any further laser spots should be generated. If Yes, the method flow is repeated from step 130. If No, the method flow is terminated (step 170).
[0102] Although in
Possible Fields of Application
[0103] The present invention can be used for laser-based material processing. This may comprise, for example, one or more of the following processes: marking, inscribing, material processing involving ablation and/or structuring, cutting, drilling, additive manufacturing and welding.
[0104] The present invention can be used if the laser has a clock frequency of 100 kHz or more, in particular several 100 kHz or in the MHz range.
[0105] Typical velocities of the laser beam on an object/workpiece are for example approx. 0.5 to approx. 10 m/s, but can also be (significantly) higher.
[0106] It should further be noted that the exemplary embodiments are merely examples which are not intended to limit the scope of protection, the possible applications and the configuration in any way. Rather, the preceding description will provide the person skilled in the art with a guideline for the implementation of at least one exemplary embodiment, whereby various changes, in particular with respect to the function and arrangement of the components described, can be made without deviating from the scope of protection as it results from the claims and combinations of features equivalent thereto.