Laser module end effector for robotic device

Patent metadata

Field	Value
Publication number	US-2022314365-A1
Application number	US-202217653639-A
Country	US
Kind code	A1
Filing date	Mar 4, 2022
Priority date	Mar 30, 2021
Publication date	Oct 6, 2022
Grant date	—

Abstract

A laser module includes a laser source and at least one air knife. The laser source is configured to be coupled to a robotic arm of a robotic device, and emit a laser beam for processing a workpiece having a workpiece surface. The air knife is configured to be coupled to the robotic arm, and discharge an airflow sheet in a direction toward a laser spot where the laser beam impinges the workpiece surface, for clearing contaminants generated by impingement of the laser beam.

First claim

What is claimed is:

1 . A laser module, comprising:
a laser source configured to be coupled to a robotic arm of a robotic device, and emit a laser beam for processing a workpiece having a workpiece surface; and at least one air knife configured to be coupled to the robotic arm, and discharge an airflow sheet in a direction toward a laser spot where the laser beam impinges the workpiece surface, for clearing contaminants generated by impingement of the laser beam.

2 . The laser module of claim 1 , wherein:
the laser source is one of an ultraviolet (UV) laser source configured to emit a UV laser beam, or an infrared (IR) laser source configured to emit an IR laser beam.

3 . The laser module of claim 1 , wherein:
the laser source is configured to emit the laser beam as a pulsed laser beam.

4 . The laser module of claim 1 , further comprising:
a laser module mounting fixture configured to support the laser source and the air knife, and coupled the laser module to the robotic arm.

5 . The laser module of claim 1 , wherein the at least one air knife comprises:
a pair of air knives configured to be positioned on opposite sides of the laser beam, and each configured to discharge an airflow sheet in a direction toward the laser spot.

6 . The laser module of claim 1 , further comprising:
a conditioning module turning mirror configured to redirect the laser beam emitted by the laser source; and a laser scanner configured to receive the laser beam from the conditioning module turning mirror, and pass the laser beam out of a scanner exit window while scanning the laser beam over a scan field on the workpiece surface.

7 . The laser module of claim 6 , further comprising:
a conditioning module housing configured to house the conditioning module turning mirror; and a conditioning module purge system configured to positively pressurize the conditioning module housing, to thereby prevent entry of the contaminants into the conditioning module housing.

8 . The laser module of claim 6 , further comprising:
a sensor housing configured to house the laser scanner, and having a faceplate having a scanner window cutout sized complementary to the scanner exit window, and forming an air gap between the scanner exit window and the faceplate; and a sensor housing purge system having a fan configured to draw ambient air into the sensor housing, and discharge the ambient air through the air gap to blow the contaminants away from the scanner exit window.

9 . The laser module of claim 6 , further comprising:
a fixed focus lens located upstream of the laser scanner, and configured to focus the laser beam on the workpiece surface.

10 . The laser module of claim 9 , further comprising:
a beam expander mounted upstream of the fixed focus lens and downstream of the conditioning module turning mirror, and configured to change a diameter of the laser beam.

11 . The laser module of claim 1 , further comprising:
at least one imaging device configured to image the workpiece surface, and perform at least one of: transmitting, to a display monitor, images of the workpiece surface and surrounding area for visual monitoring of the workpiece during processing by the laser beam; transmitting, to a processor, images of the workpiece surface for performing at least one of:
determining a location and orientation of the workpiece within a manufacturing cell containing the laser module;
determining a location of one or more geometric features of the workpiece;
monitoring the effectiveness of the laser beam in processing the workpiece;
determining whether the workpiece is being processed within process tolerances;
generating a record of the processing of the workpiece;
calibrating a laser scanner of the laser module, the laser scanner configured to scan the laser beam over a scan field on the workpiece surface; and
calibrating a tool center point of the robotic arm.

12 . A laser module, comprising:
a laser source configured to be coupled to a robotic arm of a robotic device, and emit laser beam pulses; and a laser scanner configured to receive the laser beam pulses from the laser source, and scan the laser beam pulses over a scan field on a workpiece surface of a workpiece; and at least one air knife configured to be coupled to the robotic arm, and discharge an airflow sheet in a direction toward a laser spot where the laser beam pulses impinge the workpiece surface.

13 . A method of processing a workpiece, comprising:
emitting a laser beam from a laser source of a laser module coupled to a robotic arm of a robotic device; and emitting, from at least one air knife of the laser module, an airflow sheet in a direction toward a laser spot where the laser beam impinges a workpiece surface, for clearing contaminants generated by impingement of the laser beam.

14 . The method of claim 13 , wherein emitting the laser beam from the laser source comprises one of the following:
emitting an ultraviolet (UV) laser beam from a UV laser source; or emitting an infrared (IR) laser beam from an IR laser source.

15 . The method of claim 14 , wherein emitting an IR laser beam from an IR laser source comprises:
maintaining the laser module in an upright orientation when emitting the laser beam from the UV laser source.

16 . The method of claim 13 , further comprising:
redirecting, using a conditioning module turning mirror of the laser module, the laser beam emitted by the laser source; receiving, at a laser scanner of the laser module, the laser beam from the conditioning module turning mirror; and scanning, using the laser scanner, the laser beam over a scan field on the workpiece surface.

17 . The method of claim 16 , wherein scanning the laser beam over a scan field comprises:
scanning the laser beam over a hexagonal scan field on the workpiece surface.

18 . The method of claim 17 , wherein scanning the laser beam over a hexagonal field comprises:
moving, via the robotic arm, the laser module to a first spatial location relative to the workpiece surface; scanning, using the laser scanner, the laser beam over a first hexagonal scan field having 6 side portions each having a pair of corner portions defining opposing ends of the side portion; moving, via the robotic arm, the laser module to a second spatial location; scanning, using the laser scanner, the laser beam over a second hexagonal scan field on the workpiece surface such that one of the side portions and associated corner portions of the second hexagonal scan field respectively overlaps one of the side portions and associated corner portions of the first hexagonal scan field; moving, via the robotic arm, the laser module to a third spatial location; and scanning, using the laser scanner, the laser beam over a third hexagonal scan field, on the workpiece surface such that one of the side portions and associated corner portions of the third hexagonal scan field respectively overlaps one of the side portions and associated corner portions of the first hexagonal scan field, and another one of the side portions and associated corner portions of the third hexagonal scan field respectively overlaps one of the side portions and associated corner portions of the second hexagonal scan field.

19 . The method of claim 13 , further comprising:
positively pressurizing a conditioning module housing containing the conditioning module turning mirror, to thereby prevent entry of the contaminants into the conditioning module housing.

20

Assignees

• Boeing Co

Inventors

• Johnson Matthew C
• Cardon Lisa Ann
• Smith Matthew W
• Mortvedt Soren

Classifications

• B23K26/032

  using optical means · CPC title

• B23K26/106

  inside the workpiece · CPC title

• B23K26/382

  by boring · CPC title

• B23K26/082 Primary

  Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head · CPC title

• B23K26/048

  by controlling the distance between laser head and workpiece · CPC title