US 7,324,867 B2 · Controller for a laser using predictive models of materials processing

Abstract

Predictive models of physical parts of the laser processing system part determined. These predictive models are used to determine how the physical system will actually react. The predicted reaction from the models is used as feedback in order to produce the control signals. These physical models therefore adjust to the operation of the system, much in the way that actual feedback would adjust the operation of the system. However, the system may be used at faster speeds, where the actual feedback could not be produced fast enough. Different kinds of modeling are described, including in-position feedback which models sharp movements of the laser system, trajectory models which superimpose the commanded curve over the predicted actual curve to determine errors in trajectory, and constant/variable energy density controls.

Claims32

Dependent claims

A system, comprising;

a laser beam control part which produces a laser beam;
and
a computer based controller, controlling said laser control part, said controller producing outputs which control said laser beam control part and which are based on plural predictive models, which plural predictive models include all of at least a first model representing actual response characteristics of a motion system for a laser, and a second model indicative of an energy profile delivered by the laser, which plural predictive models predict how the laser beam control part will react to said outputs, including predicting a lag in distance and in time that will exist between a commanded parameter and an actual response of said laser beam control part to each of said plural predictive models including at least both said first and second models, and controls said laser beam control part based on said predicted lag, and said controller operating to synchronize said plural models as part of the controlling.

A method, comprising:

forming a model of at least one element of a system that applies a laser beam to a process material, which plural predictive models include all of at least a first model representing actual response characteristics of a motion system for a laser, and a second model indicative of an energy profile delivered by the laser;
synchronizing results from said plural models, and using said plural models to predict at least one of a predicted position of a laser beam motion system, and in position modification which adjusts production of laser movement commands based on real-time differences between actual and commanded positions, a trajectory optimization technique which curve fits between a commanded trajectory and a predicted trajectory that is predicted using said model and determines errors in trajectory between said commanded and predicted trajectories, command feed forward, maintaining a constant energy density application or maintaining a variable energy density application including predicting a lag in distance and in time that will exist between a commanded parameter and an actual response and controls said laser beam control port based on said predicted lag, and
forming an output to control a laser beam based on said predicted position.

Dependencies are inferred from the claim text.

Controller for a laser using predictive models of materials processing

Life of this patent

Controller for a laser using predictive models of materials processing

Life of this patent

Abstract

Claims32