Investigation of detector and detection distance for developing a novel operating power detection prototype in laser processing

Abstract Existing methods for detecting the output power of processing lasers are often limited by their inability to efficiently integrate into automated closed-loop feedback control systems or by their complexity in adapting to commercial machines. This article presents a cost-effective prototype that consists primarily of a monitoring laser diode, functioning as a detector, and a digital multimeter for recording feedback signals. The prototype works like an external monitor, regardless of the original structure of the processing machine and the processing process, and feedbacks the detection content in the form of digital signals for efficient calibration. A series of benchmarking experiments were conducted with a commercial powermeter to verify the prototype’s feasibility and explore its detection capabilities. For the detection of objects at distances from 100 mm to 300 mm, with rated powers ranging from 100 mW to 40 W, the prototype’s detection accuracy ranged from 98.488% to 99.623%. These findings demonstrate that the prototype has the potential to provide valuable real-time insights into the behavior of processing lasers and in a manufacturing process. The ultimate goal for the proposed prototype would be to become a plug-and-play system, with the potential to seamlessly integrated into commercial machining systems, to achieve closed-loop feedback control.