LASER CUTTING APPARATUS THAT PERFORMS GAP SENSOR CALIBRATION AND REFLECTED LIGHT PROFILE MEASUREMENT, AND CORRELATION TABLE GENERATION METHOD FOR LASER CUTTING APPARATUS

Abstract

A laser cutting apparatus includes a laser oscillator; an output control unit for a laser beam; a cutting head configured to emit the laser beam; a gap sensor; an axial mechanism configured to activate the cutting head; an axial control unit; a detection unit configured to detect reflected light intensity; a storage unit configured to store an output value of the laser beam, reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism; and a correlation table generation unit configured to output an instruction to operate the axial mechanism and the laser oscillator, and generates a correlation table configured to obtain a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information.

Claims

1. A laser cutting apparatus comprising: a laser oscillator configured to generate a laser beam; an output control unit configured to control an output of the laser beam; a cutting head configured to emit the laser beam to a processing object; a gap sensor configured to detect a distance between the cutting head and the processing object; an axial mechanism configured to activate the cutting head; an axial control unit configured to instruct the axial mechanism to operate; a detection unit configured to detect intensity of a laser beam that is reflected from the processing object and returned to the laser oscillator; a storage unit configured to store an output value of the laser beam from the output control unit, reflected light intensity detected by way of the detection unit, a detection value of the gap sensor, and positional information of the axial mechanism; and a correlation table generation unit configured to output an instruction to operate the axial mechanism while causing the laser oscillator to output the laser beam, to the axial control unit and the output control unit, and configured to generate a correlation table for obtaining a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value of the gap sensor and the positional information, based on the output value of the laser beam, the reflected light intensity, the detection value of the gap sensor, and the positional information.

2. A laser cutting apparatus comprising: a laser oscillator configured to generate a laser beam; an output control unit configured to control an output of the laser beam; a cutting head configured to emit the laser beam to a processing object; a gap sensor configured to detect a distance between the cutting head and the processing object; an axial mechanism configured to activate the cutting head; an axial control unit configured to instruct the axial mechanism to operate; a detection unit configured to detect intensity of a laser beam that is reflected from the processing object and returned to the laser oscillator; a storage unit configured to store reflected light intensity detected by way of the detection unit, a detection value of the gap sensor, and positional information of the axial mechanism; and a correlation table generation unit configured to output an instruction to continuously operate the axial mechanism while causing the laser oscillator to output the laser beam at a constant laser beam output, to the axial control unit and the output control unit, and configured to generate a correlation table for obtaining a correlation between the positional information and the reflected light intensity, and a correlation between the detection value of the gap sensor and the positional information, based on the reflected light intensity, the detection value of the gap sensor, and the positional information.

3. The laser cutting apparatus according to claim 1, wherein when the correlation table generation unit controls the axial control unit to move the cutting head, while controlling the output control unit to cause the laser oscillator to output a laser beam, the correlation table generation unit operates the axial mechanism in synchronization with a vertical direction and a horizontal direction in relation to the processing object.

4. The laser cutting apparatus according to claim 2, wherein when the correlation table generation unit controls the axial control unit to move the cutting head, while controlling the output control unit to cause the laser oscillator to output a laser beam, the correlation table generation unit operates the axial mechanism in synchronization with a vertical direction and a horizontal direction in relation to the processing object.

5. The laser cutting apparatus according to claim 1, wherein when the correlation table generation unit controls the axial control unit to move the cutting head, while controlling the output control unit to cause the laser oscillator to output a laser beam, the correlation table generation unit operates the axial mechanism in a stepwise manner, and changes a laser output in each step.

6. A correlation table generation method for a laser cutting apparatus, the method comprising: while, based on an instruction, a laser oscillator outputs a laser beam and a cutting head emits the laser beam to a processing object, and an axial mechanism is operated to activate the cutting head, detecting a distance between the cutting head and the processing object by way of a gap sensor, and detecting, by way of a detection unit, intensity of a laser beam that is reflected from the processing object and returned to the laser oscillator; storing, in a storage unit, an output value of the laser beam, reflected light intensity detected by way of the detection unit, a detection value of the gap sensor, and positional information of the axial mechanism; and generating a correlation table for obtaining a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value of the gap sensor and the positional information, based on the output value of the laser beam, the reflected light intensity, the detection value of the gap sensor, and the positional information.

7. A correlation table generation method for a laser cutting apparatus, the method comprising: while, based on an instruction, a laser oscillator outputs a laser beam at a constant output and a cutting head emits the laser beam to a processing object, and an axial mechanism is operated to activate the cutting head, detecting a distance between the cutting head and the processing object by way of a gap sensor, and detecting, by way of a detection unit, intensity of a laser beam that is reflected from the processing object and returned to the laser oscillator; storing, in a storage unit, reflected light intensity detected by way of the detection unit, a detection value of the gap sensor, and positional information of the axial mechanism; and generating a correlation table for obtaining a correlation between the positional information and the reflected light intensity, and a correlation between the detection value of the gap sensor and the positional information, based on the reflected light intensity, the detection value of the gap sensor, and the positional information.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a schematic configuration diagram of a laser cutting apparatus of one embodiment of the present invention;

[0019] FIG. 2 is a flowchart illustrating an operation of a laser cutting apparatus in a first embodiment;

[0020] FIG. 3A is a diagram illustrating states where a cutting head is raised stepwise, and stopped at a position in a distance z.sub.1, and a position in a distance z.sub.2, from a work surface;

[0021] FIG. 3B is a characteristic graph illustrating a correlation between beam output intensity (W) and reflected light intensity (W), in the case where the cutting head is stopped at the position in the distance z.sub.1, an output of a laser beam of a laser oscillator is changed, and the reflected light intensity is measured by way of a detection unit;

[0022] FIG. 3C is a characteristic graph illustrating a correlation between beam output intensity (W) and reflected light intensity (W), in the case where the cutting head is stopped at the position in the distance z.sub.2, an output of a laser beam of the laser oscillator is changed, and the reflected light intensity is measured by way of the detection unit;

[0023] FIG. 3D is a characteristic graph illustrating a correlation between a distance from the work surface and reflected light intensity, in which the correlation is obtained from a correlation table of Table 1;

[0024] FIG. 3E is a characteristic graph illustrating a correlation between a distance from the work surface and a detection value of the gap sensor, in which the correlation is obtained from the correlation table of Table 1;

[0025] FIG. 4 is a flowchart illustrating an operation of a laser cutting apparatus in a second embodiment;

[0026] FIG. 5A is a diagram illustrating states where the cutting head is continuously raised from the work surface, and the laser oscillator continuously outputs a constant laser beam;

[0027] FIG. 5B is a characteristic graph illustrating a correlation between a distance from the work surface and reflected light intensity, in which the correlation is obtained from the correlation table of Table 2; and

[0028] FIG. 5C is a characteristic graph illustrating a correlation between a distance from the work surface and a detection value of the gap sensor, in which the correlation is obtained from the correlation table of Table 2.

DETAILED DESCRIPTION OF THE INVENTION

[0029] Embodiments of the present invention are hereinafter described with reference to the drawings.

First Embodiment

[0030] FIG. 1 is a schematic configuration diagram of a laser cutting apparatus of one embodiment of the present invention. As illustrated in FIG. 1, the laser cutting apparatus includes a controller 10, a laser oscillator 20, an axial mechanism 30, a cutting head 40, and a gap sensor 50. The laser oscillator 20 generates a laser beam, and supplies the laser beam to the cutting head 40 via an optical path. A processing object 60 is processed with a beam-like laser beam emitted from the cutting head 40. The axial mechanism 30 activates the cutting head 40 in a horizontal direction (X-axis and Y-axis directions) and a vertical direction (Z-axis direction). The gap sensor 50 is attached to a tip portion of the cutting head 40, moves together with the cutting head 40, and detects a distance between the tip portion of the cutting head 40 and a surface of the processing object 60.

[0031] The controller 10 includes: a correlation table generation unit 101; an axial control unit 102 that instructs the axial mechanism 30 to operate; an output control unit 103 that outputs an instruction for the laser oscillator 20 to control the output of a laser beam; and a storage unit 104. The laser oscillator 20 includes a detection unit 201 that detects intensity (reflected light intensity) of a laser beam that is reflected from the processing object 60 and returned to the laser oscillator 20. Since the reflected light returning to the laser oscillator 20 may damage the laser oscillator 20, the detection unit 201 measures the reflected light intensity in order to obtain allowable reflected light intensity.

[0032] When the detection unit 201 measures the reflected light, the output control unit 103 outputs laser output instructions in a consecutive way (CW) or a pulsed way (PW). When the output control unit 103 outputs the laser output instructions in a pulsed way, there is an effect to reduce the cumulative damages to the laser oscillator 20 due to reflected light.

[0033] While the laser oscillator 20 outputs a laser beam, the correlation table generation unit 101 outputs instructions to the axial control unit 102 and the output control unit 103, respectively, in accordance with a single trigger, in order to operate the axial mechanism 30. Here, a trigger generation unit (not illustrated) generates a single trigger at predetermined timing at a preliminary stage before processing.

[0034] The storage unit 104 stores: an output value of a laser beam (beam output intensity) that is output from the output control unit 103; reflected light intensity detected by way of the detection unit 201; a detection value of the gap sensor 50; and positional information of the axial mechanism 30. The correlation table generation unit 101 reads the output value of the laser beam, the reflected light intensity, the detection value, and the positional information stored in the storage unit 104, and generates a correlation table for obtaining a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information.

[0035] Table 1 illustrates an example of the correlation table generated by way of the correlation table generation unit 101. In Table 1, distances z.sub.1 to z.sub.m from the work surface represent the positional information of the axial mechanism, in which the distance z.sub.1 represents the distance from the work surface when the cutting head 40 rises one step, and the distance z.sub.m represents the distance from the work surface when the cutting head 40 finishes the rising operation.

TABLE-US-00001 TABLE 1 DISTANCE z.sub.1 FROM BEAM OUTPUT p.sub.1 p.sub.2 . . . p.sub.n WORK SURFACE INTENSITY REFLECTED LIGHT i.sub.11 i.sub.12 . . . i.sub.1n INTENSITY GAP SENSOR s.sub.1 s.sub.1 . . . s.sub.1 DETECTION VALUE DISTANCE z.sub.2 FROM BEAM OUTPUT p.sub.1 p.sub.2 . . . p.sub.n WORK SURFACE INTENSITY REFLECTED LIGHT i.sub.21 i.sub.22 . . . i.sub.2n INTENSITY GAP SENSOR s.sub.2 s.sub.2 . . . s.sub.2 DETECTION VALUE . . . . . . . . . . . . . . . . . . DISTANCE z.sub.m FROM BEAM OUTPUT p.sub.1 p.sub.2 . . . p.sub.n WORK SURFACE INTENSITY REFLECTED LIGHT i.sub.m1 i.sub.m2 . . . i.sub.mn INTENSITY GAP SENSOR s.sub.m s.sub.m . . . s.sub.m DETECTION VALUE

[0036] Based on an instruction to output a laser beam from the laser oscillator 20, and an instruction to operate the axial mechanism 30, the correlation table generation unit 101 can obtain an output value of the laser beam, reflected light intensity detected by way of the detection unit 201, a detection value of the gap sensor 50, and positional information of the axial mechanism 30. This allows for simultaneously performing gap sensor calibration as a preliminary operation before processing, and profile measurement for predicting reflected light to be generated during the processing. Therefore, the operating rate of the laser cutting apparatus can be improved.

[0037] In order to generate a correlation table, it is required to operate the axial mechanism 30, while changing the output of a laser beam of the laser oscillator 20. A control method thereof and a correlation obtained from the correlation table generation unit 101 are described with reference to the flowchart in FIG. 2 and the diagrams in FIGS. 3A to 3E.

[0038] Firstly, the correlation table generation unit 101 outputs an instruction to output a laser beam from the laser oscillator 20, and an instruction to operate the axial mechanism 30, to the axial control unit 102 and the output control unit 103 (Step S301). The axial control unit 102 causes the axial mechanism 30 to raise the cutting head 40 one step, to which the gap sensor 50 is attached, above the work surface of the processing object 60. For example, the axial control unit 102 raises the cutting head 40 to a distance z.sub.1 from the work surface (the distance z.sub.1 is positional information of the axial mechanism). In addition, when the cutting head is stopped, the axial control unit 102 causes a laser beam to be emitted to the processing object 60, while the output control unit 103 changes the output of the laser beam of the laser oscillator 20 (Step S302).

[0039] Subsequently, the detection unit 201 detects intensity (reflected light intensity) of a laser beam that is reflected from the processing object 60 and returned to the laser oscillator 20; and the gap sensor 50 detects a distance between the tip portion of the cutting head 40 and the surface of the processing object 60 (Step S303). Then, the storage unit 104 stores: an output value of a laser beam that is output from the output control unit 103; reflected light intensity detected by way of the detection unit 201; a detection value of the gap sensor 50; and positional information of the axial mechanism 30 (Step S304).

[0040] Subsequently, the correlation table generation unit 101 determines whether the rising operation of the cutting head by way of the axial mechanism 30 is finished (Step S305); and if the operation is not finished (NO in Step S305), the processing returns to Step S302, and the axial control unit 102, the detection unit 201, the storage unit 104, and the correlation table generation unit 101 perform the operations from Step S302 to S304. The operations from Step S302 to Step S305 are repeated until the rising operation by way of the axial mechanism 30 is finished. When the rising operation is finished (YES in Step S305), the correlation table generation unit 101 reads an output value of the laser beam (beam output intensity), reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism, from the storage unit 104, and generates a correlation table; and the present processing ends.

[0041] In this manner, in the present embodiment, the correlation table generation unit 101 stops the cutting head 40 and changes the output of the laser beam in each step, thereby making it possible to obtain an output value of the laser beam (beam output intensity), reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism, in each step from the work surface. Therefore, by generating a correlation table, the correlation table generation unit 101 can obtain a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information.

[0042] Note that a detection value of the gap sensor and positional information of the axial mechanism can be obtained regardless of the output of the laser beam; therefore, a detection value of the gap sensor and positional information of the axial mechanism can be detected in a continuous manner as well, instead of a stepwise manner. In the flowchart illustrated in FIG. 2, after raising the cutting head 40 one step and stopping the cutting head 40, the output of the laser beam is changed, and an output value of a laser beam (beam output intensity), reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism are obtained; however, the output value of the laser beam (beam output intensity), reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism may be obtained by changing the output of the laser beam at a position in a stand-by state before raising the head 40 one step.

[0043] FIG. 3A illustrates the states where the cutting head 40 is raised stepwise, and stopped at a position in a distance z.sub.1, and a position in a distance z.sub.2, from the work surface. The distances z.sub.1 and z.sub.2 from the work surface are positional information of the axial mechanism. FIGS. 3B to 3E are characteristic graphs illustrating a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information, which are obtained from the correlation table of Table 1.

[0044] FIGS. 3B and 3C are characteristic graphs illustrating a correlation between the beam output intensity (W) and the reflected light intensity (W), in the case where the cutting head 40 is stopped at the position in the distance z.sub.1 and the position in the distance z.sub.2, the output of the laser beam of the laser oscillator 20 is changed, and the reflected light intensity is measured by way of the detection unit 201. The width of one step of raising the cutting head 40 (corresponding to distance z.sub.2 -distance z.sub.1) can be arbitrarily set up; and if the accuracy of detection is desired to be higher, the width of one step may be set up smaller.

[0045] FIG. 3D is a characteristic graph illustrating a correlation between a distance from the work surface and reflected light intensity, at a certain output value of the laser beam, in the case where the cutting head 40 is raised stepwise. Note that, since the output of the laser beam is changed, the characteristic graph such as that in FIG. 3D is obtained for each output value of the laser beam. FIG. 3E is a characteristic graph illustrating a correlation between a distance from the work surface and a detection value of the gap sensor, in the case where the cutting head 40 is raised stepwise.

[0046] In this manner, the correlation table generation unit 101 raises the cutting head 40 stepwise, to which the gap sensor 50 is attached, and changes the output of the laser beam in each step, above the work surface of the processing object 60. As a result, the use of the correlation table of Table 1 allows for obtaining three correlations: a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information.

Second Embodiment

[0047] In the first embodiment, the correlation table generation unit 101 obtains three correlations: a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information. In contrast, in the present embodiment, the correlation table generation unit 101 maintains the laser output at a constant level, continuously raises the cutting head 40, to which the gap sensor 50 is attached, and obtains a correlation between positional information of the axial mechanism and reflected light intensity, and a correlation between a detection value of the gap sensor and positional information of the axial mechanism.

[0048] The configuration of the laser cutting apparatus used in the present embodiment is the same as the configuration of the laser cutting apparatus illustrated in FIG. 1. The present embodiment differs from the first embodiment in operations, in which the correlation table generation unit 101 controls the output control unit 103 to maintain the laser output at a constant level, and controls the axial control unit 102 to continuously move the cutting head 40. In the present embodiment, the correlation table generation unit 101 sets up the laser output at a lower level, and prevents the peak of reflected light intensity from exceeding a constant value, even if the cutting head 40 is continuously moved.

[0049] In the flowchart illustrating the operations of the laser cutting apparatus in the present embodiment illustrated in FIG. 4, Step S302 is replaced with Step S402, and Step S304 is replaced with Step S404, which are the difference from the flowchart illustrated in FIG. 3. Specifically, in Step S402, the axial control unit 102 causes the axial mechanism 30 to continuously raise the cutting head 40, and the output control unit 103 causes the laser oscillator 20 to continuously emit a constant beam output, which are the difference from Step S302 of FIG. 3. Further, in Step S404, the storage unit 104 does not store an output value of a laser beam, which is the difference from Step S304 of FIG. 3.

[0050] Table 2 illustrates an example of the correlation table generated by way of the correlation table generation unit 101. In Table 1, the distance z.sub.1 represents the distance from the work surface when the cutting head 40 starts a rising operation, and the distance z.sub.m represents the distance from the work surface when the cutting head 40 finishes the rising operation.

TABLE-US-00002 TABLE 2 DISTANCE z.sub.1 FROM REFLECTED LIGHT i.sub.12 WORK SURFACE INTENSITY GAP SENSOR DETECTION s.sub.1 VALUE . . . . . . . . . DISTANCE z.sub.m FROM REFLECTED LIGHT i.sub.m2 WORK SURFACE INTENSITY GAP SENSOR DETECTION s.sub.m VALUE

[0051] FIG. 5A is a diagram illustrating the states where the correlation table generation unit 101 causes the cutting head 40 to continuously rise from the position in the distance z.sub.1 from the work surface, and causes the laser oscillator 20 to continuously output a constant laser beam. FIG. 5B is a characteristic graph illustrating a correlation between a distance from the work surface and reflected light intensity, in which the correlation is obtained from the correlation table of Table 2. FIG. 5C is a characteristic graph illustrating a correlation between a distance from the work surface and a detection value of the gap sensor, in which the correlation is obtained from the correlation table of Table 2. The distance from the work surface is positional information of the axial mechanism.

[0052] In the present embodiment, since the correlation table generation unit 101 does not detect a correlation between the output value of the laser beam and the reflected light intensity, the time required for detecting a correlation can be shortened. Note that, in the present embodiment, if a correlation between the output value of the laser beam and the reflected light intensity is desired to be detected, while changing the output of the laser beam, the correlation table generation unit 101 may change the output of the laser beam, and repeat Steps S301, S402, S303 and S404 of FIG. 4, correspondingly to such changes.

[0053] In the first and second embodiments described above, when the cutting head is moved while outputting a laser beam, the correlation table generation unit 101 can control the axial control unit 102, such that the cutting head 40 is operated in synchronization with the vertical direction and the horizontal direction in relation to the processing object 60 (the cutting head is diagonally moved). Since the correlation table generation unit 101 operates the cutting head 40 in this manner, if the surface of the processing object 60 changes in quality by receiving the laser beam, the position can be changed in the horizontal direction, such that the detected information will not be affected by the change.

[0054] In the first and second embodiments, when the cutting head 40 is moved while outputting a laser beam, the correlation table generation unit 101 can control the axial control unit 102, such that the cutting head 40 is operated only in the vertical direction in relation to the processing object 60. This is because, when the instructed laser output is small, a change in quality of the surface of the processing object can be ignored, and a horizontal movement may not be required in some cases. By operating the cutting head 40 only in the vertical direction in relation to the processing object 60, the range of trial shooting of a laser beam can be narrower, and the waste of materials will be reduced.

[0055] The controller 10 of the laser cutting apparatus of the embodiments described above can be implemented by hardware, software or a combination thereof. Herein, the implementation by software means implementation by a computer that reads and executes a program. When configured with hardware, part or all of the controller 10 illustrated in FIG. 1 can be configured with, for example, an integrated circuit (IC) such as LSI (Large Scale Integrated Circuit), ASIC (Application Specific Integrated Circuit), gate array, and FPGA (Field Programmable Gate Array).

[0056] In the case in which all or part of the controller 10 is configured with software, a computer is configured with: a storage unit such as a hard disk and ROM which store a program describing all or part of the operations in Steps S301, S302, S304, S305 and S306 illustrated in the flowchart of FIG. 2, or the operations in Steps S301, S402, S404 and S306 illustrated in the flowchart of FIG. 4; DRAM which store data necessary for computation; CPU; and a bus which connects each unit; in which information necessary for computation is stored in the DRAM, and the program is operated in the CPU, whereby all or part of the functions of the controller 10 can be realized.

[0057] A program is stored by using various types of computer-readable media, and can be supplied to a computer. The computer-readable media include various types of tangible storage media. The computer-readable media include a non-transitory computer-readable medium. Examples of the computer-readable media include: a magnetic recording medium (e.g. flexible disk, magnetic tape, hard disk drive), a magneto-optical recording medium (e.g. magneto-optical disk), CD-ROM (Read Only Memory), CD-R, CD-R/W, semiconductor memory (e.g. Mask ROM, PROM (Programmable ROM), EPROM (Erasable PROM), flash ROM, and RAM (random access memory)).

EXPLANATION OF REFERENCE NUMERALS

[0058] 10: controller

[0059] 20: laser oscillator

[0060] 30: axial mechanism

[0061] 40: cutting head

[0062] 50: gap sensor

[0063] 60: processing object

[0064] 101: correlation table generation unit

[0065] 102: axial control unit

[0066] 103: output control unit

[0067] 104: storage unit

[0068] 201: detection unit