Approach to controlling laser processes with the help of AI

In the modern industrial context, laser processes, such as laser cutting and laser welding, are predominantly monitored and partially controlled in specific areas, such as process abort scenarios or axis actuator movements. Industrial driven interfaces like OPC UA or proprietary bus interface recently allow data acquisition from those control units within certain limits. This data can be augmented with highly accurate scientific data sources. In our proposed setup this is achieved by integrating laser acoustic sensors along with high-speed cameras operating in visual and thermal spectrum. The variety of available data sources offers a significant potential for further processing and analysis via Artificial Intelligence (AI), contributing to deeper process understanding and further development of enhanced control algorithms of laser material machining processes. A post-mortem annotation with quality characteristics such as dross formation, surface roughness, welding depth, porosity, crater formation, etc. deliver all premises to develop and train AI based control models. To link all data sources and annotations a common time management and time normal is required. Its time resolution depends on the fastest cycle time governing a control answer, typically executed in the range of sub milliseconds. A time scale smaller than standard AI algorithms typically deliver complex inference results. Our paper presents an approach to close the time gap by introducing a smart control platform capable of capturing and preprocessing data in real time by utilizing hardware accelerated acquisition algorithms and time management (FPGA-MPSoC). The solution was implemented, transferred to a state-of-the-art welding and cutting setup, and successfully tested. A foundation for an AI controlled laser machining process is set.