From 0855724cb0ae58b2338ce3cda72b32d26d0a2d52 Mon Sep 17 00:00:00 2001 From: makearmy Date: Fri, 10 Jul 2026 17:22:41 -0400 Subject: [PATCH] fix laser utility calculations --- .../laser-toolkit/beam-spot-size/page.tsx | 15 +- .../laser-toolkit/hatch-overlap/page.tsx | 17 ++- .../laser-toolkit/job-time-estimator/page.tsx | 5 +- .../laser-toolkit/power-lens-scaler/page.tsx | 129 +++--------------- .../laser-toolkit/pulse-overlap/page.tsx | 23 ++-- 5 files changed, 58 insertions(+), 131 deletions(-) diff --git a/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx b/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx index 6874057..a91bb90 100644 --- a/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx +++ b/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx @@ -10,7 +10,7 @@ function num(v: string) { return Number.isFinite(n) ? n : 0; } -// Spot diameter (µm) ≈ 1.27 * M² * λ(µm) * f(mm) / D(mm) +// Focused Gaussian 1/e² diameter: d = 4 M² λ f / (π D). export default function Page() { const [lambdaNm, setLambdaNm] = useState("1064"); // nm (default fiber) const [focalMm, setFocalMm] = useState("160"); // mm @@ -21,9 +21,9 @@ export default function Page() { const lamUm = num(lambdaNm) / 1000; // convert nm -> µm const f = num(focalMm); const D = num(beamDm); - const M2 = Math.max(1, num(m2)); - if (lamUm <= 0 || f <= 0 || D <= 0) return 0; - return 1.27 * M2 * lamUm * (f / D); + const M2 = num(m2); + if (lamUm <= 0 || f <= 0 || D <= 0 || M2 < 1) return 0; + return (4 / Math.PI) * M2 * lamUm * (f / D); }, [lambdaNm, focalMm, beamDm, m2]); const dMm = dUm / 1000; @@ -71,7 +71,7 @@ export default function Page() {
-
Spot diameter
+
1/e² spot diameter
{dMm.toFixed(4)} mm
{dUm.toFixed(2)} µm
@@ -82,7 +82,10 @@ export default function Page() { +

+ 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() {
Overlap
-
{overlap.toFixed(1)}%
+
{coverage.overlap.toFixed(1)}%
+ {coverage.uncovered > 0 && ( +
{coverage.uncovered.toFixed(1)}% uncovered gap
+ )}
Gap
@@ -83,10 +87,10 @@ export default function Page() {
From LPI
- {(UM_PER_INCH / Math.max(1, num(lpi)) / 1000).toFixed(4)} mm + {num(lpi) > 0 ? (UM_PER_INCH / num(lpi) / 1000).toFixed(4) : "0.0000"} mm
- {(UM_PER_INCH / Math.max(1, num(lpi))).toFixed(1)} µm + {num(lpi) > 0 ? (UM_PER_INCH / num(lpi)).toFixed(1) : "0.0"} µm
@@ -94,4 +98,3 @@ export default function Page() { ); } - diff --git a/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx b/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx index 24a1fd2..ec28886 100644 --- a/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx +++ b/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx @@ -44,7 +44,7 @@ export default function Page() { if (w <= 0 || h <= 0 || D <= 0 || v <= 0) return { t: 0, gapMm: 0, gapUm: 0, rows: 0 }; const gapMm = 25.4 / D; const gapUm = gapMm * 1000; - const rows = h / gapMm; + const rows = Math.max(1, Math.ceil(h / gapMm)); const t = rows * (w / v) * p * k; return { t, gapMm, gapUm, rows }; } else { @@ -159,7 +159,7 @@ export default function Page() { {/* Footnote */}

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 ( @@ -197,7 +153,7 @@ export default function Page() { Vector: Energy per length (J/mm) Raster: Energy per area (J/mm²) - Irradiance: W/mm² (spot/field) + Spot irradiance: W/mm² Pulse energy: J (fiber) @@ -247,32 +203,11 @@ export default function Page() { setHSrc(e.target.value)} inputMode="decimal" />

- + setFieldSrc(e.target.value)} inputMode="decimal" />
- - -
-
- - setFPeakSrc(e.target.value)} inputMode="decimal" /> -
-
- - setSigmaSrc(e.target.value)} inputMode="decimal" /> -
-
- η(f) is log-normal; 1.0 at fₚ, rolls off by σ. -
-
- {/* Destination */} @@ -302,26 +237,11 @@ export default function Page() { setHDst(e.target.value)} inputMode="decimal" />
- + setFieldDst(e.target.value)} inputMode="decimal" />
- -
-
- - setFPeakDst(e.target.value)} inputMode="decimal" /> -
-
- - setSigmaDst(e.target.value)} inputMode="decimal" /> -
-
- Adjust if you know your machine’s real power–frequency curve. -
-
- {/* Result */} @@ -348,11 +268,7 @@ export default function Page() {

)} -
-
-
η(f) source / dest
-
{result.eta1.toFixed(3)} / {result.eta2.toFixed(3)}
-
+
Dest pulse energy
@@ -366,13 +282,12 @@ export default function Page() {

- 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() {
Overlap
{result.overlapPct.toFixed(1)}%
+ {result.gapPct > 0 && ( +
{result.gapPct.toFixed(1)}% gap between pulses
+ )}
Pulses per mm
{result.pulsesPerMm.toFixed(1)}
-
Rule of thumb
-
- 60–80% overlap is common for marking; deeper engraving often higher. -
+
Pulses per spot diameter
+
{result.pulsesPerSpot.toFixed(2)}
+

+ Geometric overlap along the scan direction only. It does not predict material response; + pulse energy, spot profile, hatch spacing, and thermal accumulation also matter. +

); } -