Examples of Laser Processing Control with Machine Vision Feedback

Abstract

Manufacturing technologies using laser radiation energy are gaining increasingly new applications. It results from their numerous advantages, most of all, from the selectiveness of a laser beam within the spatial and temporal domain. Although the laser beam is a very precise tool, it restricts the tolerances of component preparation. If such increased requirements drive previous processes, it will result in the increase of manufacturing costs of these parts. Hence, solutions are sought in the mechatronics paradigm, which corrects mechanical imperfections by means of electronics and software. Examples of the above solutions are follow-up and adaptive control systems. The paper presents examples of developed and implemented control systems of laser manufacturing processes with machine vision feedback. They include remote cutting with CAM-MV and laser cladding with a thermal or geometric closed-loop.

Applied Machine Vision: Advancing Quality Assurance and Quality Control in Industrial Manufacturing

“…MV is a developing market expected to grow in the long run and has a promising future because of its ease of use, and new non-industrial uses are emerging. Industries that have already adopted MV are reaping the benefits of increased profit margins, while non-adopter competitors are lagging [39][40][41].…”

“…Calibrating the tool can reduce the positional errors of the laser beam. However, the use of a small laser spot size and the lack of filler material require not only strict tolerances for lateral positioning of the tool but also for the joint alignment and gap width to ensure fusion, adequate structural integrity, and satisfactory quality of the weld [40,41]. The problem is particularly pronounced in automated production setups using six-axis robots when welding along complex 3D trajectories.…”

“…High-power laser welding is widely used in industrial mass production, as it offers a highly flexible and accurate approach capable of producing high-speed welds. Nevertheless, due to the laser beam's small spot size, maintaining weld integrity necessitates precise tolerances in the joint alignment and the positioning of the laser beam's focal point [41]. The problem is further pronounced in robotic laser welding due to positional inaccuracies, primarily along complex double-curved trajectories.…”