Quasi-Continuous Wave Pulsed Laser Welding of Copper Lap Joints Using Spatial Beam Oscillation.

Laser beam welding of copper (Cu) using near-infrared radiation is extremely challenging due to its high thermal conductivity and large laser reflectivity. In the present study, the challenges and benefits of using spatial beam oscillation during quasi-continuous wave (QCW) pulsed laser beam welding of 0.4 mm Cu to 1 mm Cu in lap joint configuration are presented. This work demonstrates how laser beam oscillating parameters can be used to control the laser weld quality and laser weld dimensions for Cu-Cu joining. Compared to a non-oscillated laser beam, welds made using laser beam oscillation showed fewer spatters, porosities, and better surface quality. Four levels of oscillating amplitudes (0.2 mm, 0.4 mm, 0.6 mm, and 0.8 mm) and oscillating frequencies (100 Hz, 200 Hz, 300 Hz, and 400 Hz) were compared to reveal the effect of beam oscillation parameters. The weld width was mainly controlled by oscillating amplitude, while weld penetration was affected by both oscillating amplitude and frequency. As the oscillating amplitude increased, the weld width increased while the weld penetration decreased. Increasing the oscillating frequency reduced the weld penetration but had a negligible effect on the weld width. The maximum tensile force of approximately 1944 N was achieved for the joint with a high width-to-depth ratio with an oscillating amplitude of 0.8 mm and an oscillating frequency of 200 Hz.

Accuracy evaluation of hand-eye calibration techniques for vision-guided robots.

Hand-eye calibration is an important step in controlling a vision-guided robot in applications like part assembly, bin picking and inspection operations etc. Many methods for estimating hand-eye transformations have been proposed in literature with varying degrees of complexity and accuracy. However, the success of a vision-guided application is highly impacted by the accuracy the hand-eye calibration of the vision system with the robot. The level of this accuracy depends on several factors such as rotation and translation noise, rotation and translation motion range that must be considered during calibration. Previous studies and benchmarking of the proposed algorithms have largely been focused on the combined effect of rotation and translation noise. This study provides insight on the impact of rotation and translation noise acting in isolation on the hand-eye calibration accuracy. This deviates from the most common method of assessing hand-eye calibration accuracy based on pose noise (combined rotation and translation noise). We also evaluated the impact of the robot motion range used during the hand-eye calibration operation which is rarely considered. We provide quantitative evaluation of our study using six commonly used algorithms from an implementation perspective. We comparatively analyse the performance of these algorithms through simulation case studies and experimental validation using the Universal Robot's UR5e physical robots. Our results show that these different algorithms perform differently when the noise conditions vary rather than following a general trend. For example, the simultaneous methods are more resistant to rotation noise, whereas the separate methods are better at dealing with translation noise. Additionally, while increasing the robot rotation motion span during calibration enhances the accuracy of the separate methods, it has a negative effect on the simultaneous methods. Conversely, increasing the translation motion range improves the accuracy of simultaneous methods but degrades the accuracy of the separate methods. These findings suggest that those conditions should be considered when benchmarking algorithms or performing a calibration process for enhanced accuracy.

Self-mixing sensing system based on uncooled vertical-cavity surface-emitting laser array: linking multichannel operation and enhanced performance.

We compare the performance of a self-mixing (SM) sensing system based on an uncooled monolithic array of 24×1 vertical-cavity surface-emitting lasers (VCSELs) in two modes of operation: single active channel and the concurrent multichannel operation. We find that the signal-to-noise ratio of individual SM sensors in a VCSEL array is markedly improved by multichannel operation, as a consequence of the increased operational temperature of the sensors. The performance improvement can be further increased by manufacturing VCSEL arrays with smaller pitch. This has the potential to produce an imaging system with high spatial and temporal resolutions that can be operated without temperature stabilization.

Maintaining maximum signal-to-noise ratio in uncooled vertical-cavity surface-emitting laser-based self-mixing sensors.

We demonstrate a method for maintaining the maximum signal-to-noise ratio (SNR) of the signal obtained from the self-mixing sensor based on a vertical-cavity surface-emitting laser (VCSEL). It was found that the locus of the maximum SNR in the current-temperature space can be well approximated by a simple analytical model related to the temperature behavior of the VCSEL threshold current. The optimum sensor performance is achieved by tuning the laser current according to the proposed model, thus enabling the sensor to operate without temperature stabilization in a wide temperature range between -20 °C and +80 °C.