CN117245210B - Multi-laser mapping synthesis method and system for non-uniform energy distribution - Google Patents
Multi-laser mapping synthesis method and system for non-uniform energy distribution Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract
The invention relates to a multi-laser mapping synthesis method of non-uniform energy distribution and a system thereof. The distribution mapping transformation method can adopt matrix decomposition method, normal distribution decomposition method, vector synthesis method, distribution box mapping method, least square method, iterative optimization algorithm, machine learning method and other high-dimensional generalized dimension reduction transformation methods to decompose the target non-uniform energy distribution field onto each laser, thereby realizing the distribution of the energy of each laser. The invention can accurately control the position and the size of the plane power peak point. The invention can realize better laser process manufacturing effect and improve process quality through the non-uniform energy distribution field.
Description
Technical Field
The invention relates to the technical field of laser processing, such as laser additive manufacturing, laser welding or laser cutting, and the like, in particular to a beam/light spot shaping method, namely a multi-laser mapping synthesis method of non-uniform energy distribution and a system thereof.
Background
In the prior art, temperature control typically relies on a single or multiple evenly distributed heat sources, which limits the variety and precise control capability of the temperature field. Especially in application scenarios requiring fine regulation of temperature distribution, such as special material processing, precision manufacturing, etc., the prior art cannot meet the requirements of complex and dynamic temperature fields.
In laser machining, a single heat source refers to the use of a single laser to generate the energy source, i.e., a tunable ring shaper is used to split the beam into a central peak, or core beam, and a surrounding ring beam such as a ring + core, ring + ring, etc. The output single laser circular light spot is subjected to geometric segmentation and recombination, and the light spot shaping is performed by using an optical means group under the condition that the output is unchanged. The single laser light source scheme has the defects of low control freedom degree, low energy directivity and incapability of dynamic synthesis modulation, the energy distribution of the generated planar power field is fixed and can not be adjusted, the position point of the power peak is uncontrollable, and flexible dynamic adjustment can not be carried out according to the requirements of complex welding, material adding or cutting processes.
The output laser beams are not asynchronously modulated by a plurality of uniformly distributed heat sources, and the output power of each laser is always synchronous in the laser processing process, so that the power difference does not exist. Or combining a plurality of single-mode laser beams into one larger beam by means of an optical phased array and the like, and independently controlling each laser by means of optical means such as diffraction focusing and the like, wherein the laser light of the single laser overlaps with other beams in a far field to generate a diffraction pattern. The effect of dynamically modulating the power field can thus be achieved by manipulating the position angle of the diffractive optical lens group of the laser array. The multi-laser light source scheme has the defects of complex structure, high manufacturing cost, high requirement on the assembly precision of equipment and the like of an optical device.
Disclosure of Invention
The method aims at solving the problems that in the prior art, the distribution of an energy field cannot be modulated and the position and the size of a plane power peak point cannot be adjusted due to a single heat source such as single laser or a plurality of uniformly distributed heat sources such as multi-laser synchronous energy light sources. The invention provides a multi-laser mapping synthesis method and a system thereof for non-uniform energy distribution. The system comprises a plurality of independently controllable lasers, each laser can adjust the output power and frequency of the laser, and a central control unit for adjusting and controlling the single lasers according to the expected temperature field distribution, and complex temperature field distribution is formed by utilizing superposition and interference effects of the single lasers.
The invention discloses a distribution mapping transformation method, which can adopt a matrix decomposition method, a normal distribution decomposition method, a vector synthesis method, a distribution box mapping method, a least square method, an iterative optimization algorithm, a machine learning method and other high-dimensional generalized dimension reduction transformation methods, wherein the matrix decomposition method comprises an inverse Clarke transformation method, and aims to decompose a target non-uniform energy distribution field onto each laser, so that the energy of each laser is distributed. By independently controlling the output power of single laser in the processing process and utilizing the superposition characteristics of the power of the light spot and the heat affected zone in the plane, the distribution of the energy fields and the position and the size of the focus of the multi-laser output energy fields in the plane can be finely controlled.
The method comprises a system consisting of a plurality of lasers which can be controlled independently, wherein each laser can control output power and frequency independently, and a central control unit which is used for regulating and controlling a single laser according to a target non-uniform energy distribution field and forming the target non-uniform energy distribution field by utilizing superposition and interference effects.
Further, the method adopts distribution mapping transformation, decomposes the target non-uniform energy distribution field into the directions of mapping each laser on the cladding substrate plane according to the distribution of the target non-uniform energy distribution field on the cladding substrate plane, and calculates the output power and the frequency of each laser on the cladding substrate plane.
Further, the distribution mapping transformation includes a matrix decomposition method or a normal distribution decomposition method.
Further, the number of the plurality of lasers is an even number, the plurality of laser channels corresponding to the plurality of lasers are rotationally symmetrically arranged, two mutually symmetrical laser channels are set to be positive, one of the two mutually symmetrical laser channels is set to be negative, the target non-uniform energy distribution field is distributed to the laser channel in one of the symmetrical positive direction or the symmetrical negative direction according to a matrix decomposition method, the vector component of the laser corresponding to the laser channel in one direction of the target non-uniform energy distribution field is calculated, if the vector component in the direction is opposite to the set direction, the output power of the laser corresponding to the laser channel in the opposite direction of the direction is represented, and the power output value is the absolute value of the vector component.
Further, the target non-uniform energy distribution field is distributed to the laser channels in the positive direction, the vector component of the target non-uniform energy distribution field in the positive direction of the laser is calculated, if the vector component in the direction is negative, the vector component represents that no power is output in the direction, the corresponding laser channel in the negative direction outputs power, and the power output value is the absolute value of the vector component.
Further, the number of the plurality of lasers is six, and the method comprises the following steps:
step one: six laser channels correspondingly arranged by the six lasers are arranged in a rotationally symmetrical manner, the included angle between the six laser channels is 60 degrees in the view field direction perpendicular to the plane of the cladding substrate, the six lasers are independently controllable lasers, and each laser can independently receive signal instructions to generate laser beams with specified power;
step two: on the cladding substrate plane, taking the geometric centers of the shapes of the light spots projected by the six lasers as the origin of coordinates, and establishing a plane rectangular coordinate system;
step three: marking the direction of emitting laser beams along each laser channel on the plane of the cladding substrate as the plane direction with an included angle of 60 degrees, and marking the plane direction as A, B, C, D, E, F; establishing a three-phase coordinate system, wherein AD, BE and CF are two opposite direction axes on the same straight line, A, B, C is a positive direction, D, E, F is a negative direction, and the light spots respectively projected by six lasers in the plane of the cladding substrate are described as vectors of a determined plane rectangular coordinate system and are recorded as vectors of the determined plane rectangular coordinate systemThe vector directions and the magnitudes of the output powers of the six lasers are respectively shown;
step four: determining the non-uniform energy distribution field of the target to be synthesized, and marking the position of the power peak value as，/>The coordinates in the determined plane rectangular coordinate system are +.>Let it be = =>；
Step five: according to the distribution mapping transformation, vector components in three directions of A, B, C are decomposed; if it isWhen the vector component in the A direction is negative, the output power of the laser in the D direction is represented, the laser in the A direction no longer outputs power, and the power value of the laser output in the D direction is +.>Take absolute value, i.e.)>；
Step six: distributing power values in the A, B, C, D, E, F direction to the lasers at the corresponding positions to obtain output power of the lasers at the corresponding positions;
step seven: and (3) the six lasers execute the output power in the step (six), light beams project light spots on the surface of the cladding substrate, and energy fields generated by the light spots are mutually overlapped to synthesize a required target non-uniform energy distribution field.
Further, the distribution mapping in the fifth step is converted into a Clarke transformationVector decomposition is carried out to obtain vector components in three directions with an included angle of 120 degrees;
inverse Clarke transformation matrix into
，
Will beRight multiplying the transformation matrix M to obtain an output matrix: />，
a. b and c are vector component sizes output on A, B, C three phases, and if any one of a, b and c is a negative value, the absolute value of the vector component is taken as the corresponding D, E or the actual output power of the corresponding laser in the F axis direction.
Further, the distribution mapping transformation method adopted is a normal distribution decomposition method, namely, the distribution of the target non-uniform energy distribution field on the cladding substrate plane is distributed to each laser according to the normal distribution rule and mapped on the cladding substrate plane, and the output power of each laser on the cladding substrate plane is calculated.
A multi-laser additive system that synthesizes a non-uniform energy distribution field by the multi-laser map synthesis method of non-uniform energy distribution.
A multiple laser welding system that synthesizes a non-uniform energy distribution field by the multiple laser map synthesis method of non-uniform energy distribution.
The beneficial technical effects of the invention are as follows: (1) By independently controlling each laser, the positions and the sizes of the non-uniform energy distribution field and the plane power peak point of the target are accurately modulated by using distribution mapping transformation; (2) The beam shaping of different shapes can be realized according to the process requirements, and the process flexibility is improved; (3) The welding bead or the molten pool shape can be easily obtained by matching with the base material and adjusting the cladding direction, the cladding depth and the shape of the keyhole; (4) Compared with an optical shaping method, the optical path of the invention is simple, the requirements on the machining and mounting precision of equipment are lower, the mechanical device is simple, and compared with a synchronous multi-laser material adding scheme, the optical path of the invention is higher in degree of freedom and more flexible in control; (5) The invention can be matched with the vibration mirror, the mechanical displacement and other modes to carry out beam shaping, can also be matched with the optical phased array and the lens diffraction shaping method to carry out fine molten pool penetration and molten pool surface geometry control, has flexible control mode and has good compatibility with the existing other dynamic modulation technologies.
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FIG. 1 is a schematic diagram of a multiple laser distribution structure of the present invention.
FIG. 2 is a schematic diagram of the distribution of multiple laser spots of multiple lasers of the present invention projected onto a cladding substrate plane.
Fig. 3 is a schematic diagram of a six laser distribution structure according to embodiment 1 of the present invention.
Fig. 4 is a schematic diagram showing the power vector distribution and composition of the six lasers in fig. 3 according to embodiment 1 of the present invention.
Fig. 5 is a graph of power intensity of a laser corresponding to A, B, D in fig. 4 according to embodiment 1 of the present invention.
Fig. 6 is a power intensity distribution diagram of the laser according to the embodiment of the invention corresponding to A, B, D in fig. 4 after power vector synthesis.
FIG. 7 is a cross-sectional view of a molten pool formed on a cladding substrate plane by example 1 of the present invention and a multiple laser synchronized energy source. Wherein (a) in FIG. 7 is a schematic cross-sectional view of a molten pool formed by multiple laser synchronized energy sources in the plane of the cladding substrate. FIG. 7 (b) is a schematic cross-sectional view of a molten pool formed by the power intensity distribution of FIG. 6 in the plane of the clad substrate according to example 1 of the present invention.
FIG. 8 is a schematic diagram showing a comparison of the three-dimensional structure of a molten pool formed on a cladding substrate plane by example 1 of the present invention and a multiple laser synchronous energy source and a ring laser source. Wherein (a) in FIG. 8 is a schematic diagram of the three-dimensional structure of a molten pool with multiple laser synchronous energy sources on the plane of the cladding substrate. FIG. 8 (b) is a schematic view showing the perspective structure of a molten pool formed on the surface of a clad substrate according to example 1 of the present invention. Fig. 8 (c) and (d) are schematic views showing the three-dimensional structure of a molten pool formed on the surface of a cladding substrate by ring laser light sources having different sizes.
Fig. 9 is a schematic diagram of power vector distribution and synthesis of nine lasers according to embodiment 2 of the present invention.
Fig. 10 is a schematic diagram showing the normal distribution of the power intensity of the nine lasers of example 2 of the present invention.
Fig. 11 is a power intensity diagram of nine lasers according to example 2 of the present invention.
Fig. 12 is a power intensity distribution diagram after power vector synthesis of nine lasers according to example 2 of the present invention.
FIG. 13 is a cross-sectional view of a molten pool of a multiple laser synchronized energy source and a ring laser source in accordance with example 2 of the present invention. Wherein (a) in fig. 13 is a schematic cross-sectional view of a molten pool formed by multiple laser synchronized energy sources. Fig. 13 (b) is a schematic cross-sectional view of a molten pool formed by a ring laser light source. FIG. 13 (c) is a schematic cross-sectional view of a molten pool according to example 2 of the present invention.
FIG. 14 is a schematic view showing the perspective structure of a molten pool formed on the surface of a cladding substrate by nine lasers according to example 2 of the present invention.
FIG. 15 is a system diagram of a schematic formed by the steps of the method of the present invention.
Fig. 16 is a flow chart of the method of the present invention.
Detailed Description
Implementations of the invention refer to fig. 1-16.
A multi-laser mapping synthesis method of non-uniform energy distribution, the method comprising a system comprising a plurality of independently controllable lasers, as shown in fig. 1, wherein spots formed by the plurality of lasers on a cladding substrate plane are shown in fig. 2. Each laser can independently control output power and frequency, and the system further comprises a central control unit for independently controlling the power output of individual lasers according to a target non-uniform energy distribution field, which is formed by utilizing superposition and interference effects. According to the method, distribution mapping transformation is adopted, the target non-uniform energy distribution field is decomposed into directions of mapping each laser on a cladding substrate plane according to the distribution of the target non-uniform energy distribution field on the cladding substrate plane, and output power and frequency of each laser on the cladding substrate plane are calculated. The method of the distribution mapping transformation adopted comprises a matrix decomposition method or a normal distribution decomposition method.
Fig. 16 is a flow chart of the method of the present invention, mainly comprising: firstly, determining a target non-uniform energy distribution field to be synthesized; secondly, establishing a mathematical model to describe the output of the laser and the target power distribution, wherein the method is mainly described by establishing a rectangular coordinate system and a three-phase or nine-phase equal multiphase coordinate system, such as the rectangular coordinate system is used for describing the power peak position of a target non-uniform energy distribution field, and the three-phase or nine-phase coordinate system is used for describing the mapping direction of three or nine lasers on the cladding substrate plane; mapping and transforming the non-uniform energy distribution field distribution to a single laser through distribution mapping transformation; fourthly, calculating the output power of each laser; fifthly, each laser is independently controlled to output the calculated power value; and sixthly, a plurality of lasers are overlapped on the plane of the cladding substrate to synthesize a required target non-uniform energy distribution field.
If the number of the plurality of lasers is even, the matrix decomposition method can be used for carrying out the distribution mapping transformation. The method comprises the steps of rotationally symmetrically arranging a plurality of laser channels corresponding to a plurality of lasers, setting two mutually symmetrical laser channels, setting one of the two mutually symmetrical laser channels as a positive direction, setting the other one as a negative direction, distributing a target non-uniform energy distribution field to the laser channel in one of the symmetrical positive direction or the negative direction according to a matrix decomposition method, calculating vector components of the laser corresponding to the laser channel in one direction of the target non-uniform energy distribution field, and if the vector components in the direction are opposite to the set direction, representing output power of the laser corresponding to the laser channel in the opposite direction of the direction, wherein the power output value is the absolute value of the vector components.
Example 1, as shown in fig. 1-8, illustrates how to perform beam shaping of six laser beams by matrix decomposition method to meet the required cladding process requirements of path planning, weld pool shape, heat affected zone control, etc.
The multi-laser mapping synthesis method of non-uniform energy distribution in the embodiment comprises the following steps:
step one: the six laser channels correspondingly arranged by the six lasers are arranged in a rotationally symmetrical manner as shown in fig. 3, the included angle between the six laser channels is 60 degrees in the direction of the visual field perpendicular to the plane of the printing substrate, the six lasers are lasers with independent power control functions, and each laser can independently receive signal instructions to generate laser beams with specified power;
step two: on the cladding substrate plane, taking the geometric centers of the shapes of the light spots projected by the six lasers as the origin of coordinates, and establishing a plane rectangular coordinate system;
step three: marking the plane direction of the cladding substrate along the direction of the laser beam emitted by each laser as a plane direction with an included angle of 60 degrees, and marking the plane direction as A, B, C, D, E, F, as shown in fig. 4; AD. BE and CF are two opposite directional axes on the same straight line,establishing a three-phase coordinate system, recording A, B, C as a positive direction on a direction axis, D, E, F as a negative direction on the direction axis, describing light spots respectively projected by six lasers in the plane of the cladding substrate as vectors of the determined plane rectangular coordinate system, and marking asThe vector directions and the magnitudes of the output powers of the six lasers are respectively shown;
step four: determining the non-uniform energy distribution field of the target to be synthesized, and marking the position of the power peak value asAs shown in FIG. 4, ->The sitting mark of the above-determined plane rectangular coordinate system is +.>Let it be = =>，/>The direction is the displacement of the power intensity peak position on the cladding substrate plane, which is offset from the origin of the coordinate system, +.>Namely, the peak power size and the peak power direction which need to be synthesized;
step five: according to the matrix decomposition methodA vector component decomposed into A, B, C three directions; the matrix decomposition method is a set of algorithmic rules determined in advance for determining the power output of each laser to achieve the desired power field vector distribution. It should be noted that ++can also be used>Is decomposed into D, E,F or any other vector component combined in three directions;
in this embodiment, the matrix decomposition method is illustrated by the inverse Clarke transformVector decomposition was performed to obtain vector components in the three laser directions of A, B, C. It should be noted that the matrix decomposition method includes, but is not limited to, the inverse Clarke transformation described above. Corresponding matrix decomposition may be used depending on the number and distribution of lasers.
Inverse Clarke transformation matrix into，
Will beRight multiplying the transformation matrix M to obtain an output matrix: />，
a. b and c are vector component sizes output on A, B, C three phases, if any one of a, b and c is negative, the output power of the laser in the direction is not needed, the output power of the laser in the opposite direction is the actual output power of the laser in the opposite direction, and the actual output power is the absolute value of a, b and c. If for instanceThe vector component in the a direction is negative, and represents the laser output power in the D direction, and the laser in the a direction no longer outputs power. And the power value of the laser output in the D direction is +.>Take absolute value, i.e.)>。
Step six: the vector components are distributed to the lasers at the corresponding positions to obtain the output powers of the lasers at the corresponding positions, as shown in fig. 4 and 5. Wherein the output power of the laser in the A direction is 150w, the output power of the laser in the C direction is 80w, and the output power of the laser in the B direction is 50w;
step seven: the six lasers execute the output power calculated by the control unit, the light beams project light spots on the plane of the cladding substrate, and the energy fields generated by the light spots are mutually overlapped to finally synthesize the required target non-uniform energy distribution field, as shown in fig. 6.
As shown in FIG. 7, a comparison of the cross-section of a molten pool formed by Gaussian distribution energy fields of a multi-laser synchronous energy source in the plane of a cladding substrate is shown in example 1 of the present invention. Wherein (a) in FIG. 7 is a schematic cross-sectional view of a molten pool formed by multiple laser synchronized energy sources in the plane of the cladding substrate. FIG. 7 (b) is a schematic cross-sectional view of a molten pool formed by the non-uniform energy distribution field of the six lasers of example 1 of the present invention in the plane of the cladding substrate.
FIG. 8 is a schematic diagram showing a comparison of the three-dimensional structure of a molten pool formed on a cladding substrate plane by example 1 of the present invention and a multiple laser synchronous energy source and a ring laser source. Wherein (a) in fig. 8 is a schematic diagram of a molten pool three-dimensional structure of a gaussian distribution energy field of a multi-laser synchronous energy source on a cladding substrate plane. FIG. 8 (b) is a schematic view showing a three-dimensional structure of a molten pool formed by non-uniform energy distribution field of the six laser light of example 1 according to the present invention on the plane of the cladding substrate. Fig. 8 (c) and (d) are schematic views of the solid-state structure of a molten pool formed by annular energy distribution fields of annular laser light sources of different sizes on the plane of the cladding substrate. It can be seen from fig. 7 and 8 that the method of the present invention can achieve a non-uniform energy distribution field on the cladding substrate plane and has a controllable power peak position and magnitude as compared to the simultaneous multiple laser energy source and ring laser source.
Example 2, as shown in fig. 9-14, illustrates how beam shaping of nine lasers is performed by a normal distribution decomposition method to meet the cladding process requirements of required path planning, weld pool shape, heat affected zone control, and the like.
A multi-laser mapping synthesis method of non-uniform energy distribution and a system thereof are disclosed, wherein the system comprises nine independently controllable lasers, and each laser can independently adjust the output power and frequency. The system further comprises a central control unit for modulating each laser according to a targeted non-uniform energy distribution field. The method comprises the steps of synthesizing a target non-uniform energy distribution field by adopting a normal distribution decomposition method, distributing the target non-uniform energy distribution field to the direction of mapping each laser on the cladding substrate plane according to the normal distribution rule, and calculating the output power of each laser on the cladding substrate plane. It should be noted that the method of the present embodiment may be applied to any of a plurality of laser systems.
The multi-laser mapping synthesis method of non-uniform energy distribution in the embodiment comprises the following steps:
step one: nine laser channels correspondingly arranged by the nine lasers are rotationally symmetrical, the included angle between the nine laser channels is 40 degrees in the view field direction perpendicular to the plane of the cladding substrate, the nine lasers are lasers with independent power control functions, and each laser can independently receive signal instructions to generate laser beams with specified power;
step two: on the plane of the cladding substrate, a plane rectangular coordinate system is established by taking the geometric center of the shape of the light spot projected by the nine lasers as the origin of coordinates;
step three: marking the direction of the laser beam emitted along each laser channel on the plane of the cladding substrate as a plane direction with an included angle of 40 degrees, and marking the plane direction as A, B, C, D, E, F, G, H, I, as shown in fig. 9; establishing a nine-phase coordinate system, describing light spots projected by nine lasers in the plane of the cladding substrate as vectors of a determined plane rectangular coordinate system, and marking the vectors as vectors of the determined plane rectangular coordinate systemThe vector directions and the magnitudes of the output powers of the nine lasers are respectively shown;
step four: determining the non-uniform energy distribution field of the target to be synthesized, and marking the position of the power peak value as，/>The sitting sign in the defined planar rectangular coordinate system is +.>Let it be = =>，/>The direction is the displacement of the power intensity peak position on the cladding substrate plane, which is offset from the origin of the coordinate system, +.>Namely, the peak power size and the peak power direction which need to be synthesized;
step five: according to the distribution mapping transformation, willA vector component decomposed into A, B, C, D, E, F, G, H, I nine directions;
step six: distributing power values in the A, B, C, D, E, F, G, H, I direction to the lasers at the corresponding positions to obtain output power of the lasers at the corresponding positions; as shown in fig. 9 and 10, in the normal distribution, the C direction is the power peak direction, the laser output power in the C direction is 200w, the laser output power in the b and D directions is 160w, the laser output power in the a and E directions is 120w, the laser output power in the i and F directions is 80w, and the laser output power in the h and G directions is 40w;
step seven: and nine lasers execute the output power in the step six, light beams project light spots on the plane of the cladding substrate, and energy fields generated by the light spots are mutually overlapped to finally synthesize a required target non-uniform energy distribution field.
As shown in fig. 11, the power intensity of each of the nine lasers distributed according to fig. 10 in this embodiment is shown. Fig. 12 is a graph showing the target non-uniform energy distribution field of nine lasers according to the present embodiment after the power intensity distribution of each laser of fig. 10 is synthesized. FIG. 13 is a cross-sectional view of a molten pool of a multiple laser synchronized energy source and a ring laser source in accordance with example 2 of the present invention. Wherein (a) in fig. 13 is a schematic cross-sectional view of a molten pool formed by multiple laser synchronized energy sources. Fig. 13 (b) is a schematic cross-sectional view of a molten pool formed by a ring laser light source. FIG. 13 (c) is a schematic cross-sectional view of a molten pool according to example 2 of the present invention. Compared with the synchronous multi-laser energy light source and the annular laser light source, the method can realize non-uniform energy field distribution on the cladding substrate plane, and the position and the size of the power peak point can be controlled. FIG. 14 is a schematic view showing the perspective structure of a molten pool formed on the surface of a clad substrate according to example 2 of the present invention.
As shown in FIG. 15, the method can realize the synthesis of the required target non-uniform energy field distribution of multiple lasers on the cladding substrate plane by independently controlling a single laser, form the required power intensity distribution and finally realize the required molten pool shape, can match the process requirements of different laser welding, cutting or material adding, and improves the flexibility and the degree of freedom of the process.
The method of the "distribution map transformation" of the present invention is not limited to the matrix decomposition method and the normal distribution decomposition method described in embodiments 1 and 2. Least squares, iterative optimization algorithms, and machine learning methods may also be included. Wherein the least squares method measures the difference between the temperature field generated by the gaussian heat source and the desired temperature field by constructing an objective function. This objective function is minimized by adjusting heat source parameters such as position, peak intensity, etc. Iterative optimization algorithms, such as gradient descent, genetic algorithms, or particle swarm optimization, may be used to iteratively adjust the heat source parameters until an optimal solution is found. Machine learning methods, i.e., using machine learning techniques, such as neural networks, to learn the relationship between heat source parameters and temperature field distribution. Machine learning methods require a large number of data sets to train the model.
The above embodiments are exemplary and non-limiting for a person skilled in the art, and the scope of the present invention is not limited by the above embodiments, and the inventive concept embodied in this embodiment can be applied to a plurality of different number of laser systems. Any modifications that are not created are within the scope of the present method.
Claims (9)
1. The multi-laser mapping synthesis method of non-uniform energy distribution is characterized in that: the system comprises a plurality of lasers which can be controlled independently, wherein each laser can control output power and frequency independently, and the system also comprises a central control unit which is used for regulating and controlling a single laser according to a target non-uniform energy distribution field and forming the target non-uniform energy distribution field by utilizing superposition and interference effects; the method adopts distribution mapping transformation, decomposes the target non-uniform energy distribution field into the direction of mapping each laser on the cladding substrate plane according to the distribution of the target non-uniform energy distribution field on the cladding substrate plane, and calculates the output power and the frequency of each laser on the cladding substrate plane, and specifically comprises the following steps:
step one: determining a target non-uniform energy distribution field to be synthesized;
step two: establishing a mathematical model to describe the output of the laser and the power distribution of a target, and establishing a rectangular coordinate system to describe the power peak position of a non-uniform energy distribution field of the target, wherein the position of the power peak of the non-uniform energy distribution field of the target is recorded as The coordinates in the plane rectangular coordinate system are denoted as (x 0 ,y 0 ) Is marked as->Establishing a multiphase coordinate system to describe the directions of the plurality of lasers mapped on the cladding substrate plane;
step three: mapping the non-uniform energy distribution field distribution to a single laser by a distribution mapping transformation;
step four: calculating the output power of each laser;
step five: each laser is independently controlled to output a calculated power value;
step six: multiple lasers are superimposed on the cladding substrate plane to synthesize the desired target non-uniform energy distribution field.
2. The method of multi-laser mapping synthesis of non-uniform energy distribution according to claim 1, wherein: the distribution mapping transformation includes a matrix decomposition method or a normal distribution decomposition method.
3. The method of multi-laser mapping synthesis of non-uniform energy distribution according to claim 2, wherein: the number of the plurality of lasers is even, the plurality of laser channels corresponding to the plurality of lasers are arranged in a rotationally symmetrical mode, two mutually symmetrical laser channels are set to be positive, one of the two mutually symmetrical laser channels is set to be negative, the target non-uniform energy distribution field is distributed to the laser channel in one of the symmetrical positive direction or the symmetrical negative direction according to a matrix decomposition method, the vector component of the laser corresponding to the laser channel in one direction of the target non-uniform energy distribution field is calculated, if the vector component in the direction is opposite to the set direction, the output power of the laser corresponding to the laser channel in the opposite direction of the direction is represented, and the power output value is the absolute value of the vector component.
4. A multi-laser mapping synthesis method according to claim 3 and wherein: and distributing the target non-uniform energy distribution field to the laser channels in the positive direction, calculating the vector component of the target non-uniform energy distribution field in the positive direction of the laser, if the vector component in the direction is negative, representing that no power is output in the direction, outputting the power of the laser channels in the corresponding negative direction, and taking the absolute value of the power output value as the vector component.
5. The method of multi-laser mapping synthesis of non-uniform energy distribution according to claim 3 or 4, wherein: the number of the plurality of lasers is six, and the method comprises the following steps:
step one: six laser channels correspondingly arranged by the six lasers are arranged in a rotationally symmetrical manner, the included angle between the six laser channels is 60 degrees in the view field direction perpendicular to the plane of the cladding substrate, the six lasers are independently controllable lasers, and each laser can independently receive signal instructions to generate laser beams with specified power;
step two: on the cladding substrate plane, taking the geometric centers of the shapes of the light spots projected by the six lasers as the origin of coordinates, and establishing a plane rectangular coordinate system;
step three: marking the direction of emitting laser beams along each laser channel on the plane of the cladding substrate as the plane direction with an included angle of 60 degrees, and marking the plane direction as A, B, C, D, E, F; establishing a three-phase coordinate system, wherein AD, BE and CF are two opposite direction axes on the same straight line, A, B, C is a positive direction, D, E, F is a negative direction, and the light spots respectively projected by six lasers in the plane of the cladding substrate are described as vectors of a determined plane rectangular coordinate system and are recorded as vectors of the determined plane rectangular coordinate systemThe vector directions and the magnitudes of the output powers of the six lasers are respectively shown;
step four: determining the non-uniform energy distribution field of the target to be synthesized, and marking the position of the power peak value as In the determined plane rectangular coordinate system, the coordinates are (x 0 ,y 0 ) Is marked as->
Step five: according to the distribution mapping transformation, willA vector component decomposed into A, B, C three directions; if->When the vector component in the A direction is negative, the output power of the laser in the D direction is represented, the laser in the A direction no longer outputs power, and the power value of the laser output in the D direction is +.>Take absolute value, i.e.)>
Step six: distributing power values in the A, B, C, D, E, F direction to the lasers at the corresponding positions to obtain output power of the lasers at the corresponding positions;
step seven: and (3) the six lasers execute the output power in the step (six), light beams project light spots on the surface of the cladding substrate, and energy fields generated by the light spots are mutually overlapped to synthesize a required target non-uniform energy distribution field.
6. The method of multi-laser mapping synthesis of non-uniform energy distribution according to claim 5, wherein: the distribution mapping transformation in the fifth step is to transform by the inverse Clarke transformationVector decomposition is carried out to obtain vector components in three directions with an included angle of 120 degrees;
inverse Clarke transformation matrix into
Will beRight multiplying the transformation matrix M to obtain an output matrix:
a. b and c are vector component sizes output on A, B, C three phases, and if any one of a, b and c is a negative value, the absolute value of the vector component is taken as the corresponding D, E or the actual output power of the corresponding laser in the F axis direction.
7. The method of multi-laser mapping synthesis of non-uniform energy distribution according to claim 2, wherein: the method comprises the steps of distributing a target non-uniform energy distribution field to the direction of mapping each laser on the cladding substrate plane, wherein the adopted distribution mapping transformation method is a normal distribution decomposition method, namely distributing the target non-uniform energy distribution field to the direction of mapping each laser on the cladding substrate plane according to the normal distribution rule, and calculating the output power of each laser on the cladding substrate plane.
8. A multiple laser additive system, characterized by: the system synthesizes a non-uniform energy distribution field by the multi-laser mapping synthesis method of non-uniform energy distribution of any one of claims 1-4, 6-7.
9. A multiple laser welding system, characterized by: the system synthesizes a non-uniform energy distribution field by the multi-laser mapping synthesis method of non-uniform energy distribution of any one of claims 1-4, 6-7.
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