Abstract
This paper presents an experimental investigation into a high-bandwidth optical range sensor for laser materials processing stand-off control. Radiation from a low-power laser beam is focused onto a workpiece surface and light reflected from the surface is collected through a main lens and directed into an imaging lens which focuses the signal to two positions after being split by a beam splitter. The irradiances of the two beams are detected by photodiodes placed behind pinhole apertures positioned fore and aft of the two focal positions. A differential amplifier is used to generate an output signal that determines the magnitude and direction of any workpiece displacement. The system facilitates a measuring range of ±6 mm. A set of of experiments are performed and results are analysed for different setup configurations. The approximate range of instrument linearity is ±1 mm for the 75-mm focal length main less and ±2 mm for the 120-mm lens; in this linear range the optimal accuracy resolution is 1 μm. The system's effectiveness is controlling the stand-off distance of a laser cutting machine, and hence cut quality, is assessed.
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