Machining device and method for machining material

The invention relates to a machining device (10) comprising at least one machining head (16) designed to provide at least one high-energy machining beam (22), especially an electron or laser beam. Such a machining device is used to remove material from workpieces (28) or for connecting workpieces (28) by bonding, especially by means of welding. According to the invention, at least one scanning device (32) designed as an optical coherence tomograph and provided for surface scanning is associated with the machining head (16). The invention also relates to a method for machining material using a high-energy machining beam for scanning surface areas of a workpiece which is machined, not yet machined, or being machined, by means of an optical coherence tomograph.

RELATED APPLICATION DATA

This U.S. national phase application is based on international application no. PCT/EP2008/001692 filed on Mar. 4 2008 , which claimed priority to German patent application 10 2007 0016 444.2 filed on Apr. 5, 2007 and European patent application 08001774.2 filed on Jan. 31, 2008. Priority benefit of these earlier filed applications is hereby claimed, and the full disclosures of these earlier filed applications are hereby incorporated by reference herein.

BACKGROUND

1. Field of the Disclosure

The invention relates to a machining device with at least one machining head which is designed to provide at least one high-energy machining beam, in particular an electron beam or a laser beam.

2. Description of the Related Art

A machining device known from the market makes a relative motion possible between one or more workpieces to be machined and the machining head, in order to enable an eroding and/or joining machining of material. The machining head is equipped with an integrated or separately constructed source of the high-energy machining beam, for example a laser beam or an electron beam. Typical fields of application for a machining device of such a type are the eroding of material of a workpiece by means of a laser beam, or the welding of plastic parts or metal parts by means of an electron beam or a laser beam. Depending on the field of application, stringent quality demands are made of machining processes of such a type, which also require, inter alia, an exact guidance of the high-energy machining beam in relation to the workpiece, as well as a monitoring of the result of machining on the workpiece. For this purpose, a known machining device can be provided with one or more sensor devices which, using optical measuring methods (for example, light-slit methods) and/or electrical measuring methods (for example, eddy-current methods) and/or acoustic measuring methods (for example, ultrasonic methods), enable an examination of the result of machining that is necessary for quality control.

Since the sensors for the application of the known measuring methods are greatly influenced by the high-energy machining beam and/or require a mechanical contact with the surface being machined, a minimal spacing has to be maintained between the machining location of the machining beam and the measuring point at which the respective measuring method is applied. Consequently a process control for the machining beam can only take place with a time delay. The time delay results from the speed of machining and the geometrical spacing between machining location and measuring location.

SUMMARY

The object of the invention consists in making available a measuring device and a method that enable an improved process control for the process of machining with the high-energy machining beam.

With respect to the measuring device, this object is achieved, in accordance with the invention, by a machining device with the features of claim1.

Advantageous configurations of the invention are the subject-matter of dependent claims.

In accordance with the invention, the machining device is configured in such a manner that at least one scanning device taking the form of an optical coherence tomograph which is provided for a surface scanning is assigned to the machining head.

By the term ‘optical coherence tomograph’ a measuring device is understood which, with the aid of an interferometer, utilises the coherence properties of light —that is to say, the capacity of light for interference. For this purpose there is provision to separate beams of light emitted from a broadband light-source into two ray bundles with the aid of a beam-splitter device, in particular with a semitransmitting mirror. The first ray bundle is guided in a reference arm which has a known, adjustable length. The ray bundle is reflected at the end within the reference arm, is guided again within the reference arm and subsequently coupled into a detector. The second ray bundle is conducted to the surface to be gauged and is reflected there again at least partly in the direction of the coherence tomograph. The reflected light is likewise coupled into the detector in the coherence tomograph and results therein in interference with the first ray bundle. From the measuring signal generated by the detector, information can be acquired as to how long the path from the beam-splitter to the detector was for the second ray bundle. From this, a spacing between the coherence tomograph and the surface to be gauged can be ascertained.

Instead of a beam-splitter—in plate form or in cube form, for example—a fibre coupler with two separate fibre bundles which serve for coupling out the two ray bundles may also be employed.

Depending on the technical design of the coherence tomograph, a measurement takes place sequentially (in time-encoded manner) or simultaneously (spatially encoded) in the time domain or in the frequency domain. For a design of a coherence tomograph for measuring in the frequency domain in the case of time-encoded measurement, a light-source with variable wavelength, in particular a tunable laser, is employed instead of a broadband light-source provided for the other designs.

In accordance with the invention, the optical coherence tomograph is utilised for contactless scanning of a surface geometry of an opaque surface. Information about structures that are located beneath the opaque surface, on the other hand, is not acquired with the method according to the invention.

The surface scanning is effected one-, two- or three-dimensionally. A one-dimensional surface scanning provides a spacing from the coherence tomograph to the scanned surface. A two-dimensional surface scanning provides a surface contour, i.e. a line-like surface profile of the scanned surface. A three-dimensional surface scanning provides a planar image—that is to say, a surface relief of the scanned surface.

The scanning of the surface is effected with the aid of a measuring beam of light which is emitted by the coherence tomograph and reflected on the surface to be gauged. The reflected light is at least partly reflected back into the optical coherence tomograph and conducted to a detector together with a reference beam of light. Therein, surface-geometry information is acquired on the basis of the interference between the reflected portions of the measuring beam of light and the reference beam of light.

Optical coherence tomography exhibits a high resolution for the spatial geometry of the surface that is to be examined. In addition, a spacing between the machining location defined by the high-energy machining beam and the measuring location at which the surface scanning by the optical coherence tomograph takes place can be chosen to be very small, preferentially infinitesimally small. Hence only a small, in particular infinitesimal, temporal offset also obtains between machining and ascertainment of the surface, so an advantageous process control can be implemented.

Experiments have shown that the surface scanning with the aid of optical coherence tomography is not perturbed, or at worst is perturbed insignificantly, by the very bright process light which generally arises in the course of machining with high-energy process light. This is a significant advantage in comparison with other measuring methods, in which the process light in optical detectors or similar swamps out the actual measuring signals.

In one configuration of the invention there is provision that an optical reference path provided for the scanning device is guided in an optical fibre. In the case of a known reference path, which is guided as a free beam between several optical elements, stringent demands made of the quality and alignment of the optical elements that are used for this purpose have to be satisfied. In the case of guidance of the optical reference path in an optical fibre, in particular in a plastic or glass fibre, an inexpensive and compact style of construction for the reference path is achieved.

In a further configuration there is provision that the optical fibre of the reference path is applied, in particular wound, onto an expanding body which is capable of being driven by a control device. For the purpose of implementing the optical coherence tomography, a time-dependent change in the length of the reference path is necessary, which can be realised by elastic expansion of the optical fibre. For this purpose, the optical fibre of the reference path is applied onto an expanding body. The expanding body is preferentially produced from a piezoelectric material and changes its volume as a result of application of a control voltage, by which the applied optical fibre is influenced in its length. Preferentially the expanding body is of cylindrical construction and wrapped with one or more layers of the optical fibre, so that a particularly homogeneous expansion of the fibre is guaranteed.

In a further configuration of the invention, a length of the optical reference path is chosen in such a manner that a spacing between an exit plane of a measuring beam and a surface to be gauged may amount to more than 100 mm, preferentially more than 250 mm, particularly preferably more than 500 mm, in particular more than 800 mm. Consequently a contactless detection of the geometry of the surface to be machined that is being machined at the moment, or of the surface that has already been machined, is possible with a spacing that is adapted to a working spacing between a front end of the machining head facing towards the workpiece and the workpiece. Hence by virtue of the scanning device no restriction arises with regard to the positioning of the machining head in relation to the workpiece. In this connection, the expression ‘exit plane of the measuring beam of the optical coherence tomograph’ designates that plane in which the measuring beam emitted from the optical coherence tomograph in the direction of the workpiece becomes a free beam—that is to say, is no longer passing through any optical element.

In a preferred embodiment of the invention, the optical reference path is changed in its length in such a manner that a measuring range of the optical coherence tomograph along its optical axis directed towards the workpiece amounts to at least 3 mm, preferentially at least 5 mm, particularly preferably at least 8 mm. For this purpose the reference path is expanded by a similar amount of length, in particular by an identical amount of length. This means that, in the case of an expansion of the reference path by 8 mm, depth information of the scanned surface can be acquired within an interval of 8 mm.

In a further configuration of the invention, a deflecting device is provided on the scanning device, which is designed for a deflection of the measuring beam out of the scanning device onto the object of measurement and for a deflection of reflected beams emanating from the object of measurement into the scanning device. With a deflecting device the measuring beam can be guided over the surface of the workpiece independently of a relative motion between the machining head and the workpiece. Hence, for example, a spacing between a point of incidence of the high-energy machining beam on the workpiece and a measuring point of the measuring beam on the surface of the workpiece can be varied. In order to enable a detection of the surface geometry of the workpiece, there is provision furthermore to couple the beams reflected from the object of measurement at least partly into the scanning device with the deflecting device, so that the optical paths for the measuring beam and for the reflected beams are alike.

In a further configuration of the invention, the deflecting device exhibits at least one movably suspended mirror which is capable of being driven by a control device. The mirror is provided for a deflection of the measuring beam and of the reflected beams and can be swivelled in one or more directions in space in order to bring about a one-dimensional or two-dimensional relative motion of the measuring beam in relation to the surface of the workpiece, in order to enable a linear or planar scanning of the surface of the workpiece. In a preferred embodiment of the invention, the mirror is suspended on gimbals and is swivelled in several directions in space by several piezoelectric actuating elements that are capable of being driven independently of one another.

In a further configuration of the invention, an f-theta objective is arranged in the beam path between the mirror and the object of measurement. In the case of an f-theta objective, the image height is proportional to an input angle that an incident parallel bundle of light includes with the optical axis. In accordance with the invention, there is assigned to the f-theta objective a mirror on which the measuring beam impinges in such a manner that the swivelling of the measuring beam caused by the mirror causes a linear motion of the focal point of the measuring beam in a plane. By this means, the precise scanning of substantially flat surfaces is made possible, since, in contrast to a swivelling of the measuring beam relative to the surface to be scanned, no angle dependence of the reflected beams reflected from the surface arises. Rather, the measuring beam always impinges on the surface to be gauged with the same orientation and can, in the same way, also be reflected back into the coherence tomograph by the f-theta objective and the mirror and conducted to the detector together with the reference beam of light.

In a further configuration of the invention, a light-source, in particular a superluminescent diode with a wavelength of more than 900 nm, preferentially more than 1200 nm, particularly preferably 1350 nm, is provided by way of illuminating means for the scanning device. A superluminescent diode ordinarily has a coherence length from 10 nm to 50 nm and provides beams of light with a bandwidth of approximately 10 nm to 25 nm around a principal wavelength.

In a further configuration of the invention, the scanning device is integrated into the machining head in such a manner that at least one optical component is capable of being used jointly by the machining beam and by the measuring beam. In the case of the optical component that is used jointly, it is preferentially a question of a lens or a protecting glass. The lens may, in particular, have been provided for the focusing of the machining beam and of the measuring beam of light, in order to enable an adaptation to differing spacings between workpiece and machining head. The protecting glass serves to protect the optical system of the machining head and of the optical coherence tomograph. To the protecting glass there may be assigned devices provided on the machining head, such as outlets for protective gas or temperature sensors, which are intended to prevent a contamination and/or an overheating of the protecting glass. As a result, influences that arise by virtue of the machining of material can be effectively kept away from the scanning device. In this connection it may a question, for example, of vapours and/or particles of material that emanate from the weld and that, without appropriate protective mechanisms, would result in an impairment of the measuring quality of the scanning device.

In a further configuration of the invention, an at least substantially matching arrangement of a machining plane of the machining beam and a scanning plane of the measuring beam is provided. In the course of a surface machining by the machining beam, the latter is focused in such a manner that a focal point at least substantially coincides with the point of incidence of the machining beam on the surface to be machined. In accordance with the invention, the scanning device is likewise focused in such a way that the focal point of the measuring beam of light coincides with the focal point of the machining beam. Preferentially the machining beam and the measuring beam of light exhibit a confocal arrangement, i.e. their focal points coincide. In a particularly preferred version of the invention, the machining beam emerging from the machining head and the scanning beam emitted from the scanning device are arranged coaxially, so that a gauging of the machining point defined by the machining beam is made possible by the scanning device.

With respect to the method, the object formulated in the introduction is achieved by a method as disclosed and described herein. In accordance with the invention, an unmachined region of material is scanned with a measuring beam of an optical coherence tomograph, and an evaluation of the surface topography is undertaken on the basis of at least one reflected beam reflected from the workpiece. A scanning of such a type may, for example, be provided in order to be able to determine exactly the contour of a weld gap to be joined by welding and consequently to compensate tolerances in the contour of the weld gap that can be balanced out by the machine control of the machining device. In this connection, a compensation both with regard to a power density and with regard to a positioning of the focal point of the machining beam can be undertaken.

In particular, when an erosion of material in the axial direction of the machining beam is detected in the course of the scanning by the optical coherence tomograph, either the focal point can be tracked in the axial direction or the workpiece can be readjusted along the axial direction. Such an erosion of material arises, for example, regularly in the course of laser drilling. Since the high-energy machining beam is, as a rule, focused precisely to a predeterminable machining point, without an appropriate tracking due to the change of position of the working location a reduction of the efficiency of the erosion of material arises. The tracking of the focal point can in this case be brought about, for example, by changing a focal length of an optical system generating the focal point and arranged in a machining head, and/or by relocation of the machining head.

In supplement, or alternatively, with the method according to the invention there is provision to scan the working region of the high-energy machining beam and to implement a process control on the basis of the information acquired by the scanning. This is of significance both in the case of material-eroding methods, in particular laser cutting, and in the case of material-joining methods, in particular laser welding, and in the case of generating methods, in particular laser deposition welding, by means of the machining beam. In the case of an erosion of material, by virtue of the scanning of the working region it can be established immediately whether the desired surface structure has been obtained by the erosion of material. In the case of a joining of material, in particular by electron-beam welding or laser-beam welding, the surface geometry of the weld seam that is generated can be scanned, in order to obtain, by adaptation of welding parameters such as power density and pulse duration for the machining beam, a reliable joining of the materials with slight thermal influence.

In supplement, or alternatively, with the aid of the scanning device an already machined region of material can be scanned, in order to be able—for example, after cooling of the weld seam—to assess a warpage of material caused by the thermal influences and, where appropriate, to implement an adaptation of welding parameters.

DETAILED DESCRIPTION OF THE DISCLOSURE

InFIG. 1a machining device10is represented which is substantially composed of an industrial robot12and a laser-source14as well as a machining head16borne by the industrial robot12. The industrial robot12is a multi-axis robot which can bring the machining head16into various spatial positions relative to the workpiece28in order to guarantee an advantageous machining of the workpiece28. The laser-source14is connected to the machining head16by means of a flexible glass-fibre line30. In this case the laser light generated by the laser-source14is coupled into an optical system which is provided in the machining head16and which is not represented in any detail inFIG. 2. Emanating from the optical system, the laser light is directed onto the workpiece28in the form of a high-energy machining beam22.

Arranged in the machining head16in addition to the optical system for the high-energy machining beam22is an optical coherence tomograph32, which is not represented in any detail inFIG. 2and which is provided for an ascertainment of a surface structure generated by the welding operation in the region of the weld gap18and/or the weld seam20. For the planned machining operation the workpiece28is displaced in a machining direction indicated inFIG. 1while the machining head16is maintained at a substantially constant spacing and in a substantially vertical position in relation to the workpiece28with the aid of the industrial robot12.

The machining head16represented schematically inFIG. 2in the manner of a block diagram comprises two systems operating substantially independently of one another. A first optical system serves for conveying the high-energy machining beam22provided by the laser-source14. For this purpose, a redirecting device44is provided on the housing40, which exhibits a redirecting mirror48for right-angled redirection of the laser beam coupled out of the glass-fibre line30. Moreover, a focusing block50is provided for focusing the laser beam onto the machining location80on the workpiece28. For this purpose the focusing block50exhibits a mirror surface52which is concavely curved in sections and which focuses the incident expanded laser beam so that the latter forms a focal spot on the workpiece28.

In addition, the focusing block50is provided with a through-bore54which enables a passage of a measuring beam24of the optical coherence tomograph32which, in accordance withFIG. 2, is arranged above the focusing block50. Moreover, the through-bore54also permits a passage of reflected light which is reflected back on the surface of the workpiece28in the direction of the optical coherence tomograph32.

The optical coherence tomograph32includes a superluminescent diode42which is electrically connected to a control circuit34and radiates light with a wavelength of approximately 1300 nm in the direction of a beam-splitter56. At the beam-splitter56, which is constructed as a semitransmitting mirror, the light emitted from the superluminescent diode42is partly transmitted in the direction of a reference arm58. A further part of the light emitted by the superluminescent diode42is reflected on the beam-splitter56in the direction of the workpiece28and forms a measuring arm.

The reference arm58is formed by a glass-fibre winding which is applied on a spool core60manufactured from piezoelectric material. The spool core60is, in turn, electrically connected to an evaluating circuit36, in order by applying an electrical voltage to bring about a purposeful expansion of the spool core60and consequently an expansion of the glass-fibre winding of the reference arm58. The change of length of the reference arm58, which can be carried out in exemplary manner with a frequency of 200 Hz and with an expansion of 8 mm for the reference arm58, changes the propagation-time of the light of the superluminescent diode42coupled into the reference arm58.

By interaction of the light coupled into the reference arm58with the reflected beam26reflected back from the workpiece28, an interference of the two beams of light, i.e. an addition or a subtraction of the light-waves, takes place. The light intensity arising in this connection can be ascertained by a photodiode62which is connected to the evaluating circuit36. With knowledge of the length of the reference arm58obtaining instantaneously in the given case, and of the light intensity obtaining at the photodiode62, an inference can be drawn as to the spacing between the optical coherence tomograph32and the surface of the workpiece28, so that, given suitable guidance of the measuring beam24, a surface profile of the workpiece28can be ascertained.

Although during the welding operation by action of the high-energy machining beam22on the workpiece28both a backscattering of the laser light reflected on the workpiece28and an emission of secondary light caused by thermal radiation take place, an immediate determination of the surface profile in the region of the weld or of the machining location can be realised through the use of the optical coherence tomograph32. The primary light of the machining beam22backscattered from the workpiece28and the secondary light emitted from the heated workpiece28do not satisfy the coherence condition of the measuring light emitted with a short coherence length from 10 nm to 50 nm, such as is required for an interference with the light of the superluminescent diode42coupled into the reference arm58.

As represented schematically inFIG. 2, the high-energy machining beam22, the measuring beam24and the reflected beam26reflected back into the optical coherence tomograph32are arranged coaxially relative to one another. For an adjustment of the size of the focal spot that the high-energy machining beam exhibits on the surface of the workpiece28, a focusing lens64, which is displaceable in the vertical direction in accordance withFIG. 2and which is driven by an actuating device which is not represented, is mounted in the optical system for the high-energy machining beam22.

The measuring beam24can be redirected with the aid of a deflecting device70which takes the form of a swivelling mirror with two swivel axes oriented orthogonally relative to one another, in order to enable a planar scanning of the surface of the workpiece28.

In order to protect the entire optical system, both of the high-energy machining beam22and of the optical coherence tomograph32, against undesirable environmental influences such as may arise in particular by virtue of vapours and particles emanating from the weld, a covering glass66, which is produced from a thermally stable, optically transparent material, is mounted on a lower end face of the machining head16. The covering glass66may, where appropriate, be provided with a filter coating that is transmitting merely for the light wavelengths of the machining beam22, of the measuring beam24emitted from the superluminescent diode42and of the reflected beam26. Assigned to the covering glass66is a temperature sensor72which is electrically connected to the control circuit34and which serves for detection of a thermal overload of the covering glass66. Moreover, mounted on the machining head16is a jet pipe68which is able to conduct a current of protective gas, oriented transversely relative to the optical axis of the reflected beam26and of the measuring beam24, over the covering glass66, in order to prevent a precipitation of vapours or melt particles emanating from the weld pool.

Assigned to the machining head16represented in more detail inFIG. 3, which has the same structure as the machining head16represented inFIG. 2, is a plane swivelling mirror80and also an f-theta lens arrangement82arranged in the beam path between swivelling mirror80and object of measurement28. In contrast to the machining head16represented inFIG. 2, the optical system of the machining head16according toFIG. 3is set up for the output of a parallel beam. The swivelling mirror80can be swivelled by means of actuators, which are not represented, about an axis of rotation which is arranged in a mirror plane facing towards the measuring beam on the surface of the swivelling mirror80and which, according to the representation ofFIG. 3, extends orthogonally relative to the plane of the drawing. For the purpose of clarifying the mode of action of the f-theta lens arrangement82, the measuring beam emerging from the machining head16is represented as a parallel beam but may, depending on the refractive power of the f-theta lens, also be provided in the form of a diverging or converging beam.

The measuring beam impinges on the swivelling mirror80and is deflected appropriately by the latter. The measuring beam impinging on the f-theta lens arrangement82at differing angles and at differing locations is converted by the refractive action of the f-theta lens arrangement82into a focused measuring beam, the principal ray of which always extends parallel to the optical axis of the f-theta lens arrangement82. In the exemplary embodiment represented inFIG. 3, the surface of the object of measurement28to be scanned lies in the focal plane of the measuring beam. Hence in the course of a swivelling of the swivelling mirror80about the swivel axis a linear surface region of the object of measurement28can always be scanned with constant focusing of the measuring beam. If the swivelling mirror80is additionally capable of swivelling about a further swivel axis situated in the plane of the drawing and arranged orthogonally to that described above, then on account of the lenses of the f-theta lens arrangement82, which are constructed in rotationally symmetrical manner, a two-dimensional surface scanning of the object of measurement28can be undertaken.

In the case of the use, represented schematically inFIG. 4, of the machining head16for a drilling operation, in the enlarged detail view the machining beam22and also the measuring beam24which enter a bore88are represented. The machining beam22is focused to a focal point90. In the representation according toFIG. 4the focal point90is situated at the level of the bottom of the borehole and accordingly coincides with the position of the working location at which the erosion of material by means of the machining beam22takes place. Consequently the machining beam22impinges on the working location with maximum energy density and can erode the material with maximum efficiency.

Since the working location is relocated by the erosion of material, without a regulation of the focal position for the machining beam22a reduction of the energy density occurs, since the machining beam22impinges on the working location in defocused manner. In order to avoid this, on the basis of the measuring beam24and the distance information to be ascertained therefrom there is provision to regulate the spacing between machining head16and working location in such a way that the focal point90is always situated at the level of the working location. For the purpose of changing the spacing, the machining head16and/or the workpiece can be relocated. Additionally or alternatively, the focal point can be changed by an optical system (focusing lens [64]62inFIG. 2) which generates the focal point and is arranged in the machining head.