+ Gaussian-beam estimate: d = 4 M²λf/(πD), where D is the 1/e² beam diameter at the + lens. Real spots may be larger because of lens aberration, clipping, beam expansion, and focus error. +
); } - diff --git a/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx b/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx index dbad915..34470c8 100644 --- a/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx +++ b/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx @@ -29,11 +29,12 @@ export default function Page() { setGapUm(L > 0 ? (UM_PER_INCH / L).toFixed(2) : ""); } - const overlap = useMemo(() => { + const coverage = useMemo(() => { const d = num(spotUm); const g = num(gapUm); - if (d <= 0 || g <= 0) return 0; - return Math.max(0, Math.min(100, 100 * (1 - g / d))); + if (d <= 0 || g <= 0) return { overlap: 0, uncovered: 0 }; + const signed = 100 * (1 - g / d); + return { overlap: Math.max(0, signed), uncovered: Math.max(0, -signed) }; }, [spotUm, gapUm]); const gapMm = (num(gapUm) / 1000) || 0; @@ -68,7 +69,10 @@ export default function Page() {
Overhead factor* accounts for real-world slowdowns:
- acceleration/decelleration, jump moves, polygon delays, laser on/off timing, overscan,
+ acceleration/deceleration, jump moves, polygon delays, laser on/off timing, overscan,
bidirectional settle time, and controller latency.{" "}
Typical values: Vector cuts/marks{" "}
1.05–1.15 (simple paths, long runs closer to 1.05; tiny
@@ -171,4 +171,3 @@ export default function Page() {
);
}
-
diff --git a/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx b/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx
index 6113608..3fdb31b 100644
--- a/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx
+++ b/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx
@@ -18,33 +18,10 @@ function clamp(v: number, lo: number, hi: number) {
return Math.max(lo, Math.min(hi, v));
}
-/** Default curve parameters based on rated power (very rough, editable). */
-function defaultCurveForRatedW(W: number) {
- // Peak frequency guess (kHz). Tune these to your hardware fleet.
- let fPeak = 50;
- if (W <= 35) fPeak = 25;
- else if (W <= 60) fPeak = 50;
- else if (W <= 90) fPeak = 75;
- else fPeak = 100;
-
- // Log-normal width parameter (dimensionless). Smaller = narrower peak.
- const sigma = 0.35;
- return { fPeak, sigma };
-}
-
-/** Log-normal shaped efficiency curve normalized to 1 at fPeak. */
-function etaOfF(f_kHz: number, fPeak_kHz: number, sigma: number) {
- const f = Math.max(f_kHz, 0.1);
- const r = Math.log(f / Math.max(fPeak_kHz, 0.1));
- const eta = Math.exp(-0.5 * (r / Math.max(sigma, 0.05)) ** 2);
- // Keep within [0.1, 1] to avoid absurd zeros; adjust if you want tails to hit 0.
- return clamp(eta, 0.1, 1);
-}
-
-/** Area factor from field (proxy for spot area scaling) */
-function areaFactorFromField(fieldSrc: number, fieldDst: number) {
- if (fieldSrc <= 0 || fieldDst <= 0) return 1;
- const r = fieldDst / fieldSrc;
+/** Circular spot-area ratio; pi/4 cancels. */
+function areaFactorFromDiameter(spotSrc: number, spotDst: number) {
+ if (spotSrc <= 0 || spotDst <= 0) return 1;
+ const r = spotDst / spotSrc;
return r * r;
}
@@ -59,7 +36,7 @@ export default function Page() {
const [hSrc, setHSrc] = useState('0.1'); // mm (raster line spacing)
const [fSrc, setFSrc] = useState('30'); // kHz
const [tauSrc, setTauSrc] = useState('100'); // ns pulse width
- const [fieldSrc, setFieldSrc] = useState('110'); // mm
+ const [fieldSrc, setFieldSrc] = useState('60'); // µm, 1/e² spot diameter
// DEST machine/lens
const [wDst, setWDst] = useState('50'); // rated W
@@ -67,16 +44,7 @@ export default function Page() {
const [hDst, setHDst] = useState('0.1'); // mm
const [fDst, setFDst] = useState('30'); // kHz
const [tauDst, setTauDst] = useState('100'); // ns
- const [fieldDst, setFieldDst] = useState('70'); // mm
-
- // Curve tuning / advanced
- const [advanced, setAdvanced] = useState(false);
- const srcDefaults = defaultCurveForRatedW(num(wSrc, 50));
- const dstDefaults = defaultCurveForRatedW(num(wDst, 50));
- const [fPeakSrc, setFPeakSrc] = useState(String(srcDefaults.fPeak));
- const [sigmaSrc, setSigmaSrc] = useState(String(srcDefaults.sigma));
- const [fPeakDst, setFPeakDst] = useState(String(dstDefaults.fPeak));
- const [sigmaDst, setSigmaDst] = useState(String(dstDefaults.sigma));
+ const [fieldDst, setFieldDst] = useState('40'); // µm
// Prefer adjusting speed/freq instead of exceeding 100% power
const [preferSpeedAdjust, setPreferSpeedAdjust] = useState(true);
@@ -91,21 +59,11 @@ export default function Page() {
const h2 = Math.max(num(hDst, 0), 0.000001);
const f1k = Math.max(num(fSrc, 0), 0.1);
const f2k = Math.max(num(fDst, 0), 0.1);
- const tau1_ns = Math.max(num(tauSrc, 0), 0.1);
const tau2_ns = Math.max(num(tauDst, 0), 0.1);
- const aFac = areaFactorFromField(num(fieldSrc, 0), num(fieldDst, 0));
-
- const fpk1 = Math.max(num(fPeakSrc, defaultCurveForRatedW(W1).fPeak), 0.1);
- const sig1 = Math.max(num(sigmaSrc, defaultCurveForRatedW(W1).sigma), 0.05);
- const fpk2 = Math.max(num(fPeakDst, defaultCurveForRatedW(W2).fPeak), 0.1);
- const sig2 = Math.max(num(sigmaDst, defaultCurveForRatedW(W2).sigma), 0.05);
-
- // Efficiency factors (0..1)
- const eta1 = etaOfF(f1k, fpk1, sig1);
- const eta2 = etaOfF(f2k, fpk2, sig2);
+ const aFac = areaFactorFromDiameter(num(fieldSrc, 0), num(fieldDst, 0));
// Effective average power (W) after frequency efficiency
- const P1eff = W1 * p1 * eta1;
+ const P1eff = W1 * p1;
let p2Frac = p1; // destination power fraction (0..1)
let suggestedSpeed: number | undefined;
@@ -114,7 +72,7 @@ export default function Page() {
// Helper: compute required P2eff for each match, then map to power%
const powerPercentFromEff = (P2effReq: number) => {
// P2eff = W2 * p2 * eta2 => p2 = P2eff / (W2*eta2)
- return P2effReq / (W2 * eta2);
+ return P2effReq / W2;
};
if (mode === 'vector') {
@@ -122,7 +80,7 @@ export default function Page() {
const P2effReq = P1eff * (v2 / v1);
p2Frac = powerPercentFromEff(P2effReq);
if (preferSpeedAdjust && p2Frac > 1) {
- suggestedSpeed = v1 * (W2 * eta2) / (W1 * eta1 * p1); // from p2<=1
+ suggestedSpeed = v1 * W2 / (W1 * p1); // from p2<=1
p2Frac = 1;
}
} else if (mode === 'raster') {
@@ -130,7 +88,7 @@ export default function Page() {
const P2effReq = P1eff * ((v2 * h2) / (v1 * h1));
p2Frac = powerPercentFromEff(P2effReq);
if (preferSpeedAdjust && p2Frac > 1) {
- suggestedSpeed = v1 * (W2 * eta2) * (h1 / h2) / (W1 * eta1 * p1);
+ suggestedSpeed = v1 * W2 * (h1 / h2) / (W1 * p1);
p2Frac = 1;
}
} else if (mode === 'irradiance') {
@@ -149,7 +107,7 @@ export default function Page() {
if (preferSpeedAdjust && p2Frac > 1) {
// Suggest lowering f2 to keep p2<=1: P2eff_max = W2*eta2*1
// f2_req = P2eff_max / Ep1
- const f2_req = (W2 * eta2) / Ep1; // Hz
+ const f2_req = W2 / Ep1; // Hz
suggestedFreq_kHz = Math.max(f2_req / 1e3, 0.1);
p2Frac = 1;
}
@@ -157,7 +115,7 @@ export default function Page() {
// Compute pulse metrics (for display) using **destination** settings
const p2Clamped = clamp(p2Frac, 0, 2);
- const P2eff = W2 * p2Clamped * eta2;
+ const P2eff = W2 * p2Clamped;
const f2Hz = f2k * 1e3;
const tau2_s = tau2_ns * 1e-9;
const Ep2 = P2eff / f2Hz; // J
@@ -167,8 +125,6 @@ export default function Page() {
p2Percent: clamp(p2Clamped * 100, 0, 200),
suggestedSpeed,
suggestedFreq_kHz,
- eta1,
- eta2,
P1eff,
P2eff,
Ep2,
@@ -177,13 +133,13 @@ export default function Page() {
};
}, [
mode, wSrc, wDst, pSrc, vSrc, vDst, hSrc, hDst, fSrc, fDst, tauSrc, tauDst,
- fieldSrc, fieldDst, preferSpeedAdjust, fPeakSrc, sigmaSrc, fPeakDst, sigmaDst,
+ fieldSrc, fieldDst, preferSpeedAdjust,
]);
return (
- Assumptions: Effective power includes a frequency efficiency factor η(f). Peak power uses a rectangular pulse - approximation (shape factor ≈ 1). For real MOPA sources, pulse shape and - true power–frequency maps vary by model; adjust fp and σ if you have vendor curves. + Assumptions: displayed power percentage scales average output linearly, spots are circular, + and peak power uses a rectangular pulse approximation. Confirm the result with a low-power test; + real sources can have model-specific power limits versus frequency and pulse width.
); } - diff --git a/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx b/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx index e8ce13c..fb443eb 100644 --- a/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx +++ b/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx @@ -21,16 +21,19 @@ export default function Page() { const dUm = num(spotUm); // µm if (v <= 0 || f <= 0 || dUm <= 0) { - return { spacingUm: 0, spacingMm: 0, overlapPct: 0, pulsesPerMm: 0 }; + return { spacingUm: 0, spacingMm: 0, overlapPct: 0, gapPct: 0, pulsesPerMm: 0, pulsesPerSpot: 0 }; } // distance per pulse const spacingUm = v / f; // µm (derives from v(mm/s) / (f(kHz)*1000) * 1000) const spacingMm = spacingUm / 1000; - const overlapPct = Math.max(0, Math.min(100, 100 * (1 - spacingUm / dUm))); + const signedOverlapPct = 100 * (1 - spacingUm / dUm); + const overlapPct = Math.max(0, signedOverlapPct); + const gapPct = Math.max(0, -signedOverlapPct); const pulsesPerMm = (f * 1000) / v; + const pulsesPerSpot = dUm / spacingUm; - return { spacingUm, spacingMm, overlapPct, pulsesPerMm }; + return { spacingUm, spacingMm, overlapPct, gapPct, pulsesPerMm, pulsesPerSpot }; }, [speed, freq, spotUm]); return ( @@ -68,20 +71,24 @@ export default function Page() {+ Geometric overlap along the scan direction only. It does not predict material response; + pulse energy, spot profile, hatch spacing, and thermal accumulation also matter. +
); } -