FPGA-based laser cladding system with increased robustness to optical defects

Laser cladding is a material processing technique widely used in industry for part reconstruction, coating or rapid prototyping, among other fields. When optical systems are used as sensing elements to measure the cladding area, malfunctions can occur because of interferences of suspended powder or damages to the cameras caused by laser beams. It is therefore important to provide means to detect problems affecting the optical system and, if possible, extend its life cycle by keeping correct performance even when damaged. In previous works, an FPGA-based measurement and control system for laser cladding has been proposed, which significantly outperforms other solutions used in industry, allowing some of their limitations to be overcome. This paper presents an improved FPGA system, capable of providing correct operation in the presence of suspended powder or (to some extent) other defects affecting the optical system. Experimental results obtained in an industrial part reconstruction system are presented that demonstrate the claimed contributions of the work.