Patent ID: 12214441

DETAILED DESCRIPTION

FIGS.1to3have been previously described with reference to the prior art, and their contents are intended to be referred to herein as they are common to the implementation of a controlled processing machine for carrying out a method according to the teachings of the present invention.

FIG.4ashows a schematic view of the Michelson configuration of a low coherence interferometric system with detection in the frequency domain. A collimated beam of measurement optical radiation, indicated with M, coming from a lens T and a collimated beam of the same reference optical radiation, indicated with R, coming from a reference reflective element RM—both originating from a source L—impinge in superposition on a diffraction grating G and from here, through a focusing lens, the spectral distribution of the interfering beams reaches a common incidence region C of a sensor arrangement S, where it forms an interference fringe pattern F, shown inFIG.4b.

The sensor arrangement S comprises, for example, an arrangement of photodetectors along at least one illumination axis of the incidence region (axis x in the figure). The photodetector arrangement is a linear or two-dimensional arrangement of photodetectors, preferably a linear arrangement. The illumination axis of the region of incidence is determined by the intersection between the plane defined by the angle of incidence of the measurement beam M and of the reference beam R and the sensor surface of said sensor arrangement.

FIG.4cshows the result of the processing of the acquisition of the interference fringe pattern by the photodetectors, wherein the spectrum of the interfering beams is extracted from the intensity profile ofFIG.4band by means of an FFT algorithm the frequency of the fringes is determined, which is known to depend on the phase difference of the interfering beams, namely on the corresponding difference Δp of optical lengths of the measurement and reference paths.

FIG.5ais a schematic view of the configuration of a low coherence interferometric system with a linear spatial detection. A measurement collimated beam of optical radiation, indicated by M, and a reference collimated beam of the same optical radiation, indicated by R, impinge so as to be superimposed on a common region of incidence C of a sensor arrangement S, at a predetermined angle of incidence α, where they form a pattern of interference fringes F, the extension of which on the common region of incidence is of the order of the coherence length of the optical radiation. The width of the measurement collimated beam of optical radiation and the width of the reference collimated beam of optical radiation are preferably designed so as to substantially illuminate the entire sensor arrangement. In order to increase the intensity and the contrast of the signal detected, the beams may be concentrated on the sensor in the direction that is perpendicular to the illumination axis, for example by means of a cylindrical focusing lens.

The sensor arrangement S comprises, for example, an arrangement of photodetectors along at least one illumination axis of the incidence region (axis x in the figure). The photodetector arrangement is a linear or two-dimensional arrangement of photodetectors, preferably a linear arrangement. The illumination axis of the region of incidence is determined by the intersection between the plane defined by the angle of incidence of the measurement beam M and of the reference beam R and the sensor surface of said sensor arrangement.

InFIG.5b, the graph schematically shows the variation in the lengths p of the measurement and reference optical paths, referring to the initial incident wavefront of the respective measurement and reference beams on the common region of incidence of the sensor arrangement S, in the typical configuration in which the two incident beams are symmetrical on the sensor arrangement. The x-axis indicates the position or x coordinate along the illumination axis of the photodetector arrangement. Reference numeral p1 indicates the additional length of a first optical path, for example the measurement optical path of the measurement optical radiation beam M, with respect to the initial point of incidence of the wavefront of the measurement beam M at a first end of the common region of incidence C, x1, which is the origin of the measurement axis. Reference numeral p2 indicates the additional length of a second optical path, for example the reference optical path of the reference optical radiation beam R, with respect to the initial point of incidence of the wavefront of the reference beam R at a second end of the common region of incidence, x2, which is opposite the first. Reference numeral Δp indicates the difference between the additional lengths of the two paths, p1-p2, which is zero at the middle coordinate of the sensor arrangement, and varies from a value Δpx1at the end x1of the common region of incidence to a value Δpx2at the end x2of the common region of incidence.

InFIG.5c, the top graph shows the curve Δp that corresponds to the graph inFIG.5b, and the bottom graph shows the identification of a pattern of interference fringes F on the illumination axis (x) of the sensor arrangement S that occurs when the optical lengths of the measurement and reference paths are equal. The envelope of the pattern of interference fringes F is indicated with hatching, and the respective difference Δppbetween the additional lengths of the paths of the measurement and reference optical beams is associated with the coordinate of the envelope peak, xp, by means of the upper graph.

PMand PRindicate the measurement and reference paths, the overall lengths of which may be expressed as PM=P1+p1 and PR=P2+p2, where P1 is the optical length of the measurement optical path from the low coherence optical radiation source to the first wavefront incident on the sensor arrangement, and P2 is the optical length of the reference optical path from the same low coherence optical radiation source to the first wavefront incident on the sensor arrangement, and is preferably constant. It is possible to consider P1 as composed of Pnom+d, where Pnomis the nominal length of the optical path including a first section comprised between the low coherence optical radiation source and a predetermined back-reflective surface of the optical element of which to determine the position, in its predetermined nominal position, and a second section comprised between the aforesaid back-reflective surface and the sensor arrangement S, which sections have a respective predetermined and invariant geometric length. d indicates the position offset of the optical element with respect to its nominal position. P2 is the optical length of the reference optical path, which is equivalent to the optical length Pnomof the measurement optical path in a nominal operative condition, wherein the optical element is in its predetermined nominal position.

The difference in optical length between the measurement optical path and the reference optical path is represented mathematically as:
PM−PR
and the interference fringes appear in the condition in which this is zero, that is:
PM−PR=0
a relationship that may be broken down as:
P1+p1−(P2+p2)=0
which may be written again as:
Pnom+d+p1−P2−p2=0
from which the following is deduced:
Pnom+d−P2+Δp=0
Pnom+d−Pnom+Δp=0
Δp=−d
that is, the current position of the optical element is equal to the difference between the additional lengths of the measurement optical path and the reference optical path.

Therefore, the current local position of an optical element with respect to its nominal local position, determined by a difference in optical length between the measurement optical path and the reference optical path, is attributable to a difference between the additional lengths of the measurement optical path and of the reference optical path, therefore to a movement of the pattern of interference fringes along the illumination axis x of the sensor arrangement S with respect to a nominal position, for example the median plane of said sensor arrangement S.

In the application which is the subject of the invention, the length of the reference optical path is established in such a way as to correspond to the length of the measurement optical path at the predetermined nominal position of the optical element, and the difference between (a) the current local position of said optical element and (b) the predetermined nominal local position of said optical element along the axis of the measurement beam results from the difference in length between the measurement optical path and the reference optical path, recognizable according to the position of the interference fringe pattern along the illumination axis of the region of incidence of the sensor arrangement S—if an interferometric technique with detection of the interference fringe pattern in the space domain is used, or as a function of the frequency of the interference fringe pattern—if an interferometric technique with detection of the interference fringe pattern in the frequency domain is used.

It should be noted that the local position is the position along the axis z of an area of the optical element local to the axis of the measurement optical beam that affects the element, relative to a predetermined reference system, for example an axial reference system along the propagation axis of the processing laser beam, or a Cartesian reference system of the working head. The back-reflective surface of the optical element may be the first surface of the element that the measurement beam encounters, or the surface opposite to it, depending on the quantity of optical radiation that is reflected, preferring to carry out the measurement on the basis of the higher quantity of back-reflected radiation.

The “local position” therefore indicates the absolute position of a rigid element or carries information about the position of an area of an element that is subject to deformation. It is therefore possible that the axis of the measurement beam may be dynamically controlled in a neighborhood of the axis of the processing beam so as to explore the surface of the optical element on a plane xy.

Advantageously, in the preferred case of the interferometric technique with detection of the interference fringe pattern in the space domain, a median position of the interference fringe pattern along the illumination axis of the sensor arrangement corresponds to the nominal position of the optical element. Alternatively, an end position of the interference fringe pattern along the illumination axis may correspond to the nominal position of the optical element, if this position may only vary in one direction, so that the interference pattern only moves towards the opposite end of the illumination axis.

With reference to the bottom graph inFIG.5c, the position xpof the pattern of interference fringes along the illumination axis is the intrinsic position of the envelope of the intensity of the optical radiation of said pattern of interference fringes, and this intrinsic position of the envelope of the intensity of the optical radiation of said pattern of interference fringes is—for example—the position of the peak or maximum intensity of the envelope of the optical radiation, or the average position of the photodetectors weighted with the optical intensity of the fringe envelope.

The detection of the fringe envelope may be carried out by means of optical intensity profile demodulation techniques, for example by applying a band-pass spatial filter, or high-pass and low-pass filters in a sequence, so as to reveal the only signal components corresponding to the spatial frequency of the interference fringes. For example, in a first step of processing the optical intensity data, the optical intensity detected by a matrix of sensors is integrated in the direction that is perpendicular to the development direction of the interference fringe, for example for columns of a matrix of sensors oriented so as to receive a pattern of vertically aligned interference fringes (this operation is not required if the sensor arrangement is a linear arrangement of photodetectors on which the beams are focused by means of a cylindrical lens). Subsequently, the signal generated by the photodetectors is normalized with respect to a background signal, for example extracted from an image devoid of interference fringes. Therefore, a high-pass spatial filter is applied, for example to ⅕ of the photodetector spatial frequency in order to remove the baseline and to maintain the pattern of interference fringes. Since, in this way, a signal is obtained that oscillates around zero, the absolute value of the signal is extracted and therefore a low-pass spatial filter is applied, for example to 1/25 of the photodetector spatial frequency in order to extract the envelope of the pattern of interference fringes. The position of the pattern of interference fringes is lastly obtained by detecting the position of the envelope of the fringe pattern by seeking the maximum thereof or by comparing the envelope with a predetermined model function (for example a Gaussian function) and extracting the peak of the model function.

FIG.6shows an exemplary diagram of a system object of the invention for determining the local position of at least one optical element associated with an optical path for transporting a laser beam in a working head14of a machine for laser processing of a material WP, integrated—according to the currently preferred embodiment—in a system for determining the separation distance between the working head and the material.

In the figure,100indicates a low coherence optical radiation source suitably having linear polarization, such as an LED or a super luminescent diode, for example which operates in the visible or near-infrared wavelength range. The optical radiation emitted by the source100, downstream of a suitable optical isolator120, is injected into an optical waveguide, for example an optical fiber140, and carried to a beam splitter160that is adapted to generating a measurement beam of optical radiation M, which is routed on a measurement optical path PM, and a reference optical radiation beam R that is routed on a reference optical path PR.

The measurement optical path PMand the reference optical path PRare guided paths and include optical guides (for example optical fibers) that are adapted to maintain the same polarization of the beam along the entire path.

The measurement optical path PMis conducted to the working head14of a machine for laser processing a material as described above, and possibly emerges from there towards the material WP being processed, on which it possibly impinges. The region where the measurement beam M is output corresponds to the section of the measurement head, the distance of which from the above-mentioned material is intended to be measured, for example the opening in the nozzle for supplying the flow of assist gas or the output for the laser beam.

The optical reference path PRis instead led to a return reflective element180, preferably through the interposition of an optical density filter200, of an optical dispersion compensation element220, of a sheet λ/4240and of a focusing lens260. The reflective optical element180is arranged along the reference optical path such that the optical length of that path from the beam splitter160to the reflective optical element180corresponds to the optical length of the measurement optical path from the beam splitter160to the (reflective) surface of the optical element to be monitored, that is, the position of which is to be determined, in its predetermined nominal position. The reflective optical element may be axially moved and arranged in such a way as to determine a different optical reference path length, or one of a plurality of reference optical paths including respective reflective optical elements180and having different optical lengths may be selected, to switch between methods for determining the local position of different optical elements and possibly to a method for determining the separation distance between the material being processed WP and the working head, i.e. the end of the working head proximal to the material, such as the opening of the assist gas nozzle or the beam output.

Specifically, in the case of determining the position of a plurality of optical elements interposed along the optical path for transporting the laser beam, a plurality of optical measurement paths are provided, associated with a plurality of corresponding reference optical paths, by extracting a corresponding plurality of measurement optical beams respectively associated with each of said plurality of optical elements, downstream of the reflection or diffusion from at least one back-reflective surface of each of said plurality of optical elements. The plurality of reference optical paths is arranged to lead respective separate or superimposed reference optical beams, i.e. it is determined by means of a continuous variation of the length of a basic reference optical path through an optical element for deviation and separation of the reference optical beams.

The measurement and reference optical paths PM, PRare such that the optical radiation passes through them in both directions, returning towards the beam splitter160after reflection, respectively to the at least partially back-reflective surface of the optical element and to the reflective optical element180. In the reference optical path PR, the double passage of the reference beam R through the λ/4 plate240brings about a 90° rotation of the linear polarization of the beam, which thereby assumes a linear polarization that is orthogonal to the linear polarization of the measurement beam M. The beam splitter160then performs a recombination of the measurement optical beam and of the reference optical beam and directs them, superimposed, along a detection optical path PD(common to a portion of the measurement optical path and to a portion of the reference optical path) towards the sensor arrangement S.

Both the measurement and reference optical beams are led through a cylindrical focusing lens280, which may focus the collimated beam in just one direction, in particular the direction orthogonal to the illumination axis of the sensor arrangement, with the aim of concentrating the signal along this axis, thereby optimizing the illumination of the photodetectors, and arrive at a polarizing beam splitter300that performs the separation of the measurement optical beam M from the reference optical beam R on the basis of their polarization, directing the first thereof towards a first reflective element M1 and the second thereof towards a second reflective element M2, in this last case by interposing a λ/2 plate320that may restore the original polarization. On account of this configuration, the first and the second reflective element M1, M2 direct the measurement optical beam and the reference optical beam towards the sensor arrangement S, respectively, and more precisely towards the common region of incidence of the sensor arrangement, at an angle of incidence α. The angle of incidence α may be advantageously controlled within a preset range of values in an embodiment of the system in which the reflective elements M1 and M2 are respectively moveable in translation along the axis of propagation of the relative optical beam and in rotation about an axis that is normal with respect to the incidence plane (dashed position in the figure).

Of course, in an embodiment based on an interferometric technique with detection of the pattern of interference fringes in the frequency domain, the optical detection path PDdoes not again provide for the separation of the measurement and reference beams, but comprises a spectrometer according to the architecture described inFIG.4a.

As described above, the sensor arrangement S comprises a plurality of photodetector devices, each of which is adapted to emit a particular signal representative of the optical intensity incident thereon, and these signals are transmitted, as a whole, to processing means350configured for identifying a pattern of interference fringes F that forms on the common region of incidence C of the sensor arrangement by acquiring the overall incident optical power of the superimposed measurement optical beam and reference optical beam.

Preferably, the measurement optical path and the reference optical path comprise corresponding optical elements, and in particular the reference optical path comprises a reflective return element, the reflective and optical diffusion properties of which correspond to the reflective and optical diffusion properties of the monitored optical element interposed in the measurement optical path as much as possible. Optionally, optical attenuating means may be provided, adapted to balance the intensity of the reference optical radiation reflected by said return reflective element with respect to the intensity of the measurement optical radiation reflected by the monitored optical element.

By means of the system ofFIG.6, or equivalent systems, a method for determining the local position of at least one optical element is implemented.

The method comprises generating a low coherence measurement optical radiation beam M which is led towards an optical element associated with, for example, interposed along, the optical transport path of the laser beam in a working head of a machine for laser processing of a material, and—reflected or scattered by at least one back-reflective surface of said optical element—is led through the working head14towards the sensor arrangement S.

In the case of reflective optical elements, it may be assumed that the reflection or scattering of the measurement optical beam occurs at the first surface of the element, while in the case of reflective optical elements it may be assumed that the reflection or scattering of the measurement optical beam occurs at both surfaces of the element.

The measurement optical radiation beam M specifically travels an optical measurement path from the source100to the sensor arrangement S which includes two sections having a respective predetermined and invariant geometric length when said optical element is in a predetermined nominal position corresponding to a predetermined operative condition, respectively, a first section comprised between the source100and the back-reflective surface of said optical element, and a second section comprised between the back-reflective surface of said optical element and the sensor arrangement S.

From the same source100a beam of said reference low coherence optical radiation R is generated, which is led towards the sensor arrangement S. The reference beam R travels along a reference optical path PRof optical length equivalent to the optical length of the measurement optical path PMin the nominal operative condition in which the position of said optical element is the predetermined nominal position.

The measurement beam M and the reference beam R are superimposed on the common region of incidence C of the sensor arrangement S along a preset illumination axis.

Applying an interferometric technique with detection of the pattern of interference fringes in the space domain, the position of a pattern of interference fringes F between the measurement beam M and the reference beam R along the illumination axis on the common incidence region C is detected by the processing means350and allows, as described above, determining the difference in optical length between the measurement optical path PMand the reference optical path PR, which is indicative of the difference between (a) the current local position of the optical element and (b) the predetermined nominal local position of said optical element along the axis of the measurement beam.

By applying an interferometric technique with detection of the pattern of interference fringes in the frequency domain, the frequency of a pattern of interference fringes F between the measurement beam M and the reference beam R obtained by scattering said beams in wavelength along the illumination axis on the common incidence region C is detected by the processing means350and allows, as described above, determining the difference in optical length between the measurement optical path PMand the reference optical path PR, which is indicative of the difference between (a) the current local position of the optical element and (b) the predetermined nominal local position of said optical element along the axis of the measurement beam.

The method may be implemented in real time during a processing of a material, but also before or after processing, for example to qualify the state of an optical element of the working head. The material being processed may also be absent in a monitoring step of an optical element conducted separately from a processing step, for example using a low coherence optical radiation at a wavelength maximally reflected by said optical element. In the event that the material is present when the monitoring of the optical elements takes place during a processing step, part of the measurement signal is taken which is back-reflected to a surface of the optical element of interest for which a corresponding reference optical path is selected.

With reference toFIG.7, an exemplary embodiment of the path of the processing laser beam B and of the measurement optical beam M within the working head is schematically shown.

FIG.7shows a reflective element that deflects the laser beam, such as a dichroic mirror, indicated by DM, which deflects the optical axis of propagation of the processing laser beam B from a head-entering direction to a direction of incidence on the material WP being processed. This is a configuration that is adopted in one embodiment of the working head comprising a lateral laser beam input. In this embodiment, the measurement optical radiation beam M is directed towards the optical element to be monitored downstream (and towards the material measurement region) —passing through the dichroic mirror DM without appreciable deflection—by means of a reflective optical scanning system SM, or folding mirror, the inclination of which is controlled, for example by piezoelectricity, according to the need to explore different areas of the element to control the position in which the measurement point intercepts the surface of the element. The subject element is, in the example shown without limitation, a focusing lens FL. As may be seen in the figure, the propagation direction of the measurement beam may be controlled by the inclination of the reflective optical scanning system SM so as not to be coaxially superimposed on the processing laser beam B, but to be different therefrom. A person skilled in the art will also understand that a “dual” or “opposite” configuration is possible, in which a dichroic mirror is provided, which is transparent to the processing laser beam but reflects the measurement beam coming from a lateral input.

FIGS.8a,8band8cschematically show a first condition of back-reflection or partial diffusion of the measurement optical radiation, to a first surface S1 or to a second surface S2 of the optical element E, and with possible interposition of the material WP being processed. MTdenotes the part of the measurement optical radiation beam that passes through the optical element E, and MR1and MR2denote the part of the measurement optical radiation beam that is reflected at the surfaces S1 or S2 of the optical element E. InFIG.8c, MTRdenotes the part of the measurement optical radiation beam that passes through the optical element E, but is reflected in the return path by the material WP, with MTR2the part of the measurement optical radiation which is further reflected by the surface S2 of the optical element E and with MTR2Rthe part of the measurement optical radiation beam which is further reflected by the material WP and with MTR2RTthe part of the measurement optical radiation beam which passes through the optical element E.

Another possible operative condition is shown inFIG.8d, in which the measurement optical path includes at least a third intermediate section between the first section from the source to the back-reflective surface S2 of the optical element E and the second section between the back-reflective surface S2 of the optical element E and the sensor arrangement S. Said third section is comprised between a first and a second back-reflection to the back-reflective surface S2 of the optical element and includes at least one at least partial back-reflection to the back-reflective surface S1 of the optical element E. MR2indicates the part of the measurement optical radiation beam which is reflected by the surface S2 of the optical element E, with MR21the part of the measurement optical radiation beam which is further reflected by the surface S1 of the optical element E, and with MR212the part of the measurement optical radiation beam which is reflected again by the surface S2 of the optical element E. The aforementioned third section has a respective predetermined nominal geometric and optical length under nominal conditions when the optical element is in the predetermined nominal position and/or in the predetermined operative condition.

Another possible operative condition is shown inFIG.8e, in which the optical measurement path includes at least a third intermediate section between the first section from the source to the back-reflective surface S1 of the optical element E and the second section between the back-reflective surface S1 of the optical element E and the sensor arrangement S. Said third section is comprised between a first and a second back-reflection to the back-reflective surface S1 of the optical element and includes at least one at least partial back-reflection to a back-reflective surface S2′ of a different optical element E′, also interposed along the optical transport path of the laser beam. The aforementioned third section has a respective predetermined nominal geometric and optical length when the optical element E is in the predetermined nominal position and/or in the predetermined operative condition.

The predetermined operative condition is a rest condition of the machine or a processing condition associated with predetermined processing parameters.

Moreover, the first and the second sections of the measurement optical path may include at least one at least partial back-reflection at a back-reflective surface of a different optical element interposed along the optical transport path for the laser beam or of the material being processed.

Advantageously, the described method allows verifying the positioning and the possible deformation or displacement, temporary (in process) or permanent, of an optical element associated with the optical transport path of a laser beam, such as a lens or a mirror. An optical element, in fact, may undergo changes in shape due to the temperature of the environment in which it resides, or—if flexible—due to the pressure to which it is exposed, or better due to the pressure difference established between rooms of an environment that it divides. An optical element may also be subject to changes in position due to the effect of temperature or pressure if these physical parameters affect the receiving seat thereof, for example a deformable ring, which may translate.

A specific application case is described below.

In a machine for laser cutting, drilling or welding or for the additive manufacture of three-dimensional structures by laser, comprising a working head carrying a nozzle for supplying an assist gas flow, it is desirable to control the assist gas pressure in the nozzle chamber without having to resort to the installation of ad hoc sensors. Knowledge of the assist gas pressure is also useful in determining the influence of the assist gas pressure on the propagation features of a measurement optical radiation beam propagated through the nozzle and used for example for determining the distance of the working head (of the nozzle) from the material being processed.

The pressure of the assist gas in the assist gas chamber of the nozzle may be derived indirectly from a measurement of the change in the local position of a surface of a protective optical element or boundary of the assist gas chamber interposed along the optical transport path of the processing laser beam or of an assist optical element facing said assist gas chamber, possibly outside the axis of the processing laser beam, according to a predetermined reference model indicative of a predetermined nominal relationship between the position of the surface of said optical element relative to a respective predetermined nominal position corresponding to a predetermined reference pressure value of the assist gas, and the pressure of the assist gas.

This reference model may be built starting from a direct pressure measurement and from the detection of the position of the optical element in a calibration step.

FIG.9shows a dependence relationship of the outcome of the interferometric reading, expressed in terms of variation of the local position of a surface of an optical element for protection or delimitation of the assist gas chamber along the axis of the measurement beam, from the trend (increasing, decreasing) of the pressure of the assist gas in the aforementioned chamber. Curve A represents the change in the local position of a surface of the protective optical element or boundary of the assist gas chamber as the pressure within the chamber increases. Curve B represents the change in the local position of a surface of the protective optical element or boundary of the assist gas chamber as the pressure within the chamber decreases. The hysteresis between the two curves may be attributed to non-elastic deformations of the materials involved.

In this embodiment, the reference optical path advantageously comprises an optical element corresponding to the optical protection element or to the optical assist element, arranged along the reference optical path in a position corresponding to the nominal position of the optical protection element or of the assist optical element in the measurement optical path and subject to a controlled pressure value which constitutes the aforementioned predetermined reference pressure value of the assist gas in the measurement optical path.

Similarly to the indirect pressure measurement, a further specific application case of the present invention relates to the determination of the temperature of an optical element or of a transmission medium interposed along the optical transport path of the processing laser beam or of the environment in which the element is located, if this determines a local deformation or displacement. The state of said optical element is determined by adopting a method for determining its local position as described above in which the reference beam travels along a reference optical path of optical length equal to the optical length of the measurement optical path in a nominal operative condition including a partial back-reflection of the measurement beam at a surface of the optical element when it is in the predetermined nominal position corresponding to a predetermined reference temperature value. The operating temperature of the optical element is then determined according to a predetermined reference model indicative of a nominal relationship between the position of the optical element relative to the predetermined nominal position and the temperature of the element.

A further specific application case of the method for determining the position of an optical element object of the invention relates to the determination of a perturbation of the current optical length of at least a portion of the measurement optical path with respect to the current optical length of a corresponding portion of the reference optical path.

The propagation features of the measurement optical radiation beam are influenced by the physical parameters (temperature, pressure, mechanical deformations) of the transmission medium in which it propagates, essentially since the refractive index of the transmission medium is variable according to such parameters. The method according to the invention may therefore be used for measuring refractive index variations of the crossed transmission media, for example refractive index variations induced by the pressure of the assist gas, assuming the positions of the back-reflective optical elements as static.

In a machine for laser cutting, drilling or welding of a material, or for the additive manufacturing of three-dimensional structures by laser, comprising a working head carrying a nozzle for supplying an assist gas flow, the measurement optical radiation beam is propagated through the nozzle and its propagation features are influenced by the pressure of the assist gas.

In order to improve the accuracy of the process object of the invention, the determination of the difference in optical length between the measurement optical path and the reference optical path may therefore preferably be based on a normalized optical length of the measurement optical path which is calculated starting from the geometric length and a normalized refractive index of the portion of said optical measurement path that passes through the assist gas chamber, that is the nozzle. The normalized refractive index is calculated as a function of the pressure of the assist gas in said chamber, according to a predetermined nominal relationship depending on the refractive index of the transmission medium filled by the assist gas on the pressure of said gas.

In more general terms, since the optical length of the measurement optical path is dependent on the geometric length of the path and on the refractive index of the transmission medium, the determination of the difference in optical length between the measurement optical path and the reference optical path may be based on a normalized optical length of the optical measurement path, which is calculated starting from the geometric length and a normalized refractive index of the transmission medium of said measurement optical path, or of a transmission medium of a portion of said measurement optical path, which refractive index is calculated as a function of the variation of at least one physical parameter of the transmission medium, such as the temperature according to a predetermined nominal relationship between the refractive index or reflectivity and the temperature of the element itself.

Alternatively, or in combination with the above, the determination of the optical length difference between the measurement optical path and the reference optical path may be based on a normalized optical length of the measurement optical path which is calculated starting from the normalized geometric length and from a refractive index of a material transmission medium of a portion of said measurement optical path, in which the normalized geometric length is calculated as a function of the mechanical deformation or the mechanical deformation (for example, lengthening or shortening) of said material transmission medium according to a predetermined nominal relationship.

Advantageously, the technique object of the invention allows determining a perturbation of the current optical length of at least a portion of the measurement optical path with respect to the current optical length of a corresponding portion of the reference optical path, and correcting the determined value of the local current position of the optical element along the axis of the measurement beam with respect to the nominal local position on the basis of the determined perturbation, for example by subtracting the measurement of the perturbation from the measurement of the current local position of the element (possibly after applying a correction factor). The perturbation occurs, for example, due to the variation of at least one physical parameter of the transmission medium within which the measurement optical path extends.

For these purposes, the measurement beam incident on the sensor arrangement S comprises at least one calibration measurement beam which results from the travel of a calibration measurement optical path, wherein the measurement beam is reflected or diffused by at least one back-reflective surface of a static optical element interposed along the measurement optical path, and wherein the reference beam incident on the sensor arrangement S comprises a respective calibration reference beam which results from the travel of a calibration reference optical path having an optical length equivalent to the optical length of the calibration measurement optical path in a nominal operating condition of calibration in which the geometric length and the refractive index of the transmission medium of the calibration measurement optical path are equal to the geometric length and to the refractive index of the transmission medium of the calibration reference optical path within a predetermined tolerance range. The static optical element may be, for example, the optical focusing system16of the laser beam.

Determining the perturbation of the current optical length of at least a portion of the measurement optical path includes the following operations:superimposing the calibration measurement beam and the calibration reference beam on a common incidence region of the sensor arrangement S, along the illumination axis;detecting the position of a pattern of interference fringes between the calibration measurement beam and the calibration reference beam along the illumination axis on the common region of incidence, or the frequency of a pattern of interference fringes between the calibration measurement beam and the calibration reference beam, if an interferometry technique with frequency domain detection is applied; anddetermining a difference in optical length between the calibration measurement optical path and the calibration reference optical path—indicative of a difference between (a) the geometric length of the calibration measurement optical path and the geometric length of the calibration reference optical path, and/or (b) the refractive index of the calibration measurement optical path and the refractive index of the calibration reference optical path-depending on either of the position of the pattern of interference fringes along the illumination axis of the region of incidence, or of the frequency of the pattern of interference fringes in the frequency domain.

The optical length difference between the calibration measurement optical path and the calibration reference optical path is indicative of the aforementioned perturbation of the current optical length of at least a portion of the measurement optical path.

The correction of the determined value of the current local position of the optical element along the axis of the measurement beam with respect to the nominal local position on the basis of the determined perturbation is carried out, for example, by subtracting the calibration value from the main measurement value.

Improvements of the invention will be described hereinafter in the present description.

In particular, a solution to increase the difference interval between the lengths of the measurement and reference paths measurable by the technique of the invention is to exploit partial back-reflections at the surfaces of at least one different optical element interposed along the path of the processing laser beam and of the measurement optical radiation beam, or of exploiting reference optical paths of predetermined lengths different from the length of the main reference optical path.

In an embodiment, the measurement beam incident on the sensor arrangement S comprises a main measurement beam which results from the travel of a main measurement optical path with reflection from the back-reflective surface of the optical element being measured and with transmission through any other optical element interposed along the optical path of the processing laser beam upstream of said optical element being measured, and at least one additional multiplexed measurement beam which results from the travel of an additional measurement optical path, with reflection from the back-reflective surface of said optical element being measured and having a geometric length greater than the geometric length of the main measurement optical path, for example because it includes at least a partial back-reflection on the surface of a different optical element interposed along the optical path of the processing laser beam and of the measurement optical radiation beam.

In this embodiment, the method of the invention is based on the detection of the position of an additional pattern of interference fringes on the common incidence region C of the sensor arrangement S, determined by the interference between the additional measurement beam and the reference beam. In an interferometric technique with detection of the pattern of interference fringe in the space domain, the additional pattern of interference fringes has for example (i) a peak or maximum intensity of the envelope of the optical radiation distinct from, for example lower than, the peak or maximum intensity of the envelope of the optical radiation of the main pattern of interference fringes between the main measurement beam and the reference beam, or (ii) an intrinsic position of the envelope of intensity of the optical radiation that is different from the intrinsic position of the optical radiation intensity of the main interference pattern, if it appears at the same time as the main interference pattern.

In the above condition, a difference in optical length is therefore determined between the additional measurement optical path and the reference optical path, which is indicative of a difference between (a) the current local position of said optical element and (b) the predetermined nominal local position of said optical element along the axis of the measurement beam, as a function of the position of the additional pattern of interference fringes along the illumination axis of the region of incidence, or of the frequency of said pattern of interference fringes in the frequency domain.

In a different embodiment, the reference beam incident on the sensor arrangement S comprises a main reference beam which results from the travel of a main reference optical path and at least one additional multiplexed reference beam which results from the travel of an additional reference optical path having a geometric length different from the geometric length of the main reference optical path.

In this embodiment, the method of the invention is based on the detection of the position of an additional pattern of interference fringes on the common incidence region of the sensor arrangement S, determined by the interference between the measurement beam and the additional reference beam.

Also in this case, in an interferometric technique with detection of the pattern of interference fringe in the space domain, the additional pattern of interference fringes has for example (i) a peak or maximum intensity of the envelope of the optical radiation distinct from, for example lower than, the peak or maximum intensity of the envelope of the optical radiation of the main pattern of interference fringes between the measurement beam and the main reference beam, or (ii) an intrinsic position of the envelope of intensity of the optical radiation that is different from the intrinsic position of the optical radiation intensity of the main interference pattern, if it appears at the same time as the main interference pattern.

In the event that several distinct operating intervals are not alongside or superimposed on the sensor arrangement, but are sufficiently separated to alternately show the respective interference fringes, the selection of the pattern of interference fringes occurs by selecting the additional reference path.

In the above condition, a difference in optical length is therefore determined between the measurement optical path and the additional reference optical path, which is indicative of a difference between (a) the current local position of said optical element and (b) the predetermined nominal local position of said optical element along the axis of the measurement beam, as a function of the position of the additional pattern of interference fringes along the illumination axis of the region of incidence, or of the frequency of said pattern of interference fringes in the frequency domain.

Conveniently, the accurate determination of the position of an optical element, and better still of each optical element of the transport path of the laser beam, which may be selected through the consideration of a respective reference optical path which may be associated with the measurement optical path, allows a control unit of the laser processing machine to operate in feedback the correction or control of some operating parameters, such as the pressure of the assist gas, or to emit an alarm signal and stop each working process, if it determines that an optical element is in an abnormal position. This is particularly useful for improving the safety of a manufacturing process, for example.

It should be noted that the proposed embodiment for the present invention in the foregoing discussion has a purely illustrative and non-limiting nature of the present invention. A man skilled in the art can easily implement the present invention in different embodiments which however do not depart from the principles outlined herein and are therefore included in the present patent.

This is particularly applicable with regard to the possibility of using different low coherence optical radiation wavelengths to those cited, or measurement and reference optical paths having interposed optical elements that are different from those illustrated inFIG.6purely by way of non-limiting example.

Of course, the principle of the invention being understood, the manufacturing details and the embodiments may widely vary compared to what has been described and illustrated by way of a non-limiting example only, without departing from the scope of the invention as defined in the appended claims.