Multi-beam special-shaped laser cladding head based on hierarchical shaping disc

Abstract

This invention discloses a multi-beam irregular-shaped laser cladding head based on a graded shaping disk, comprising a beam splitting module; a laser shaping module including a collimation unit, a rotating graded shaping unit, and a second focusing unit arranged sequentially along the optical path; the rotating graded shaping unit includes at least two layers of coaxial and independently rotating shaping disks, each layer of shaping disk having multiple sets of holes spaced along its circumference, each set of holes having at least one through hole, the through hole being an irregular-shaped hole or a light-transmitting hole, and the diameter of the light-transmitting hole being larger than the circumcircle diameter of the irregular-shaped hole. The beneficial effects of this invention are: uniform beam splitting is achieved through prism combination, the optical path is stable, and the exclusive yielding mechanism of multiple independent rotating shaping disks and large-diameter light-transmitting holes, combined with a collaborative control system, enables rapid online synchronous switching of multiple irregular-shaped light spots without shutdown. This design effectively eliminates obstruction and diffraction, ensures the purity of the light spot, improves efficiency while optimizing the quality of the cladding layer, and suppresses porosity and cracks.

Description

Technical Field

[0001] This invention relates to the field of laser cladding technology, and in particular to a multi-beam irregular-shaped laser cladding head based on a graded shaping disk. Background Technology

[0002] In laser cladding, the shape of the energy distribution of the output spot has a decisive influence on the uniformity of the molten pool temperature, the powder melting efficiency, and the quality of the cladding layer. Traditional circular spot energy has a Gaussian distribution with strong energy at the center and weak energy at the edges, which can easily lead to overheating at the center of the cladding layer and poor fusion at the edges. In contrast, irregularly shaped spots (such as rectangular, elongated, and annular spots) can provide a more uniform linear or planar energy distribution, effectively improving the overlap quality and suppressing the formation of cracks and pores.

[0003] Existing methods for obtaining irregularly shaped light spots mainly involve offline replacement of diffractive optical elements or irregularly shaped apertures. This method has significant drawbacks: First, replacing elements requires interrupting processing and disassembling and calibrating, which is cumbersome and severely restricts production efficiency. Second, a single element corresponds to only one shape, which cannot meet the needs of complex processes for rapid and flexible switching of multiple irregularly shaped light spots. Third, when applied to multi-beam parallel processing, existing solutions are difficult to simultaneously and independently shape and switch each sub-beam online, resulting in poor structural compatibility.

[0004] Therefore, there is a need for a laser cladding head that can quickly and synchronously switch between multiple irregularly shaped light spots online without stopping the machine or replacing components, and that is compatible with multi-beam architectures. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is that the prior art requires offline replacement of components for irregular spot switching, which is inefficient, has few types, and is difficult to meet the problem of multi-beam synchronous online shaping.

[0006] The above-mentioned technical problems are solved by the following technical solution: The present invention proposes a multi-beam irregular laser cladding head based on a graded shaping disk, which includes a beam splitting module to split a single incident laser beam into multiple sub-beams; The laser shaping module includes a collimation unit, a rotational grading shaping unit, and a second focusing unit arranged sequentially along the optical path. The rotary grading shaping unit includes at least two coaxial shaping disks that rotate independently. Each shaping disk has multiple sets of holes spaced along the circumference. Each set of holes has at least one through hole. The through hole is an irregularly shaped hole or a light-transmitting hole, and the diameter of the light-transmitting hole is larger than the outer circle diameter of the irregularly shaped hole. By independently rotating the shaping disks of each layer, the target irregular-shaped aperture group on any layer is aligned with the corresponding sub-beam, and the light-transmitting aperture groups at the corresponding positions on the other layers are aligned with the sub-beam. Only the irregular-shaped apertures of the working layer perform shaping and modulation on the sub-beam, and different irregular-shaped lasers are switched online for output.

[0007] In a preferred embodiment of the multi-beam irregular laser cladding head based on a graded shaping disk described in this invention: the beam splitting module includes a central beam splitting prism, disposed on the incident optical axis, which splits a single incident laser beam into two symmetrical horizontal laser beams; two reflecting prisms, symmetrically disposed on both sides of the central beam splitting prism, which reflect the two horizontal laser beams into two parallel vertical laser beams respectively; and two beam splitting prisms, respectively disposed below the two reflecting prisms, which split the two vertical laser beams into four sub-beams that are parallel to each other and arranged in a 2×2 array.

[0008] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk described in this invention: the central beam splitter is an isosceles right-angled triangular prism, with its right-angled face facing the incident laser and its two inclined faces facing the reflecting prisms on both sides respectively. Both reflecting prisms are isosceles right-angled triangular prisms, with their inclined surfaces facing the two inclined surfaces of the central beam splitter, and their right-angled surfaces facing the beam splitter below.

[0009] In a preferred embodiment of the multi-beam irregular-shaped laser cladding head based on the graded shaping disk described in this invention: the rotating graded shaping unit includes three layers of shaping disks arranged coaxially and each of which can rotate independently, namely the first shaping disk, the second shaping disk and the third shaping disk, and the irregular-shaped holes distributed on each layer of shaping disk are different.

[0010] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk described in this invention: multiple sets of holes on each layer of the shaping disk are evenly distributed at equal central angles along the circumference of the same radius, with the central angle interval between adjacent sets of holes being 45°, and a total of 8 sets of holes are provided on the entire disk.

[0011] In a preferred embodiment of the multi-beam irregular-shaped laser cladding head based on the graded shaping disk of the present invention: the sub-beams are divided into left and right groups, the first group of sub-beams corresponds to the hole position group in the first angular direction on the shaping disk, and the second group of sub-beams corresponds to the hole position group in the second angular direction which is 180° different from the first angular direction; each group of holes includes two through holes arranged coaxially in the radial direction, which respectively correspond to the optical axis positions of a group of two sub-beams.

[0012] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk of the present invention: the aperture D2 of the light-transmitting hole and the outer circle diameter D1 of the irregular hole satisfy D2≥1.5×D1.

[0013] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk described in this invention: it also includes a control system, which includes three independent drive mechanisms and a motion controller. The three independent drive mechanisms are respectively connected to the first shaping disk, the second shaping disk and the third shaping disk in a one-to-one transmission connection. The motion controller synchronously sends switching commands to the three sets of drive mechanisms within the same control cycle, driving the three-layer shaping disks to rotate according to the synchronous motion curve; the state switching is triggered only when the three-layer shaping disks reach the target angle at the same time and the position deviation is less than the preset threshold.

[0014] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk described in this invention: the shape of the irregular hole includes at least one of the following: triangle, square, rhombus, hexagon, ellipse, strip, or ring.

[0015] In a preferred embodiment of the multi-beam irregular laser cladding head based on the graded shaping disk of the present invention: the beam splitting module further includes a first focusing unit respectively disposed below the two beam splitting prisms, for focusing and outputting the split sub-beams; the collimating unit includes two collimating lenses, which respectively receive the left and right sets of sub-beams; the second focusing unit includes two focusing lenses, which respectively focus the two sets of shaped lasers onto the processing surface.

[0016] The beneficial effects of this invention are as follows: uniform beam splitting and optical path stability are achieved through prism combination; by utilizing the exclusive yielding mechanism of multi-layer independent rotating shaping disks and large-aperture light-passing holes, combined with a collaborative control system, multiple irregular light spots can be switched online quickly and synchronously without stopping the machine. This design effectively eliminates obstruction and diffraction, ensures the purity of the light spot, and optimizes the quality of the cladding layer while improving efficiency and suppressing pore cracks. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. Obviously, the drawings described below only relate to some embodiments of the present invention and are not intended to limit the present invention. Wherein: Figure 1 A schematic diagram of the overall structure of a multi-beam irregular laser cladding head based on a graded shaping disk is shown. Figure 2 A cross-sectional view of a multi-beam irregular-shaped laser cladding head based on a graded shaping disk is shown; Figure 3 A cross-sectional view of the beam splitter module is shown; Figure 4 A cross-section of the beam splitter module is shown. Figure 2 ; Figure 5 A schematic diagram of the beam splitter module is shown; Figure 6 A structural diagram of the laser shaping module is shown; Figure 7 A structural diagram of the rotary grading shaping unit is shown. Figure 8 A partially enlarged view of the laser shaping module is shown; Figure 9 A schematic diagram of the laser shaping module is shown. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0019] The terminology used in this invention is that which is currently widely used in the art in consideration of the function of the invention; however, these terms may vary according to the intent of those skilled in the art, precedent, or new technology in the art. Furthermore, specific terms may be chosen by the applicant, and in such cases, their detailed meanings will be described in the detailed description of the invention. Therefore, the terms used in this specification should not be construed as simple names, but rather based on their meanings and the overall description of the invention.

[0020] Reference Figures 1-7 This embodiment provides a multi-beam irregular laser cladding head based on a graded shaping disk, including a beam splitting module 1. The beam splitting module 1 is located at the front end of the optical path. Its core function is to split the input single incident laser beam and convert it into multiple sub-beam outputs, laying the foundation for subsequent multi-beam parallel processing. The laser shaping module 2 is located after the beam splitting module 1. It includes a collimation unit 21, a rotational grading shaping unit 22, and a second focusing unit 23 arranged sequentially along the optical path. The beam passes through collimation, shaping, and focusing processes in sequence and finally acts on the workpiece. The rotating graded shaping unit 22 is the core component for realizing the online switching of irregular light spot function of the present invention. The rotating graded shaping unit 22 includes at least two layers of coaxial shaping disks 221 that rotate independently. That is, the rotation angle of each layer of shaping disk 221 does not interfere with each other and can be controlled individually. Each layer of shaping disk 221 has multiple sets of holes spaced along the circumference. Each set of holes has at least one through hole 222. The through holes 222 are divided into two types: one type is irregular hole 2221 used to change the shape of the beam, and the other type is light-transmitting hole 2222 used for light transmission. The diameter of the light-transmitting hole 2222 is larger than the outer circle diameter of the irregular hole 2221. By independently driving the rotation of each shaping disk 221, the relative position of each shaping disk 221 with the beam is determined. In any working state, one of the layers is selected as the working layer and rotated so that the target irregular hole 2221 group on that layer is precisely aligned with the corresponding sub-beam path. At the same time, the remaining shaping disks, i.e. the non-working layers, are rotated so that the light-transmitting hole 2222 group at their corresponding positions is aligned with the sub-beam path.

[0021] Since the aperture of the light-transmitting aperture 2222 is larger than the outer circle diameter of the irregular aperture 2221, the light-transmitting aperture on the non-working layer can provide sufficient light-transmitting space, so that the sub-beam will not be physically blocked or edge-cut by the aperture wall when passing through the non-working layer. Therefore, in the optical path, only the irregular aperture 2221 of the current working layer will have an effective physical restriction and shaping modulation effect on the sub-beam, while the other layers only exist as light-transmitting channels. In this way, it is only necessary to control the shaping disks of different layers to rotate to the working position to switch the output of different shaped lasers online and quickly without stopping the machine to replace any optical components.

[0022] Figures 2-5 As an optional embodiment, the beam splitting module 1 is the core component for realizing laser beam splitting and spatial arrangement. Internally, it mainly consists of three parts: a central beam splitting prism 11, a reflecting prism 12, and a beam splitting prism 13. Through a specific geometric layout, it achieves optical path conversion. The central beam splitting prism 11 is positioned on the incident optical axis of the system, serving as the first-stage beam splitting structure. When a single incident laser beam irradiates the central beam splitting prism 11, the prism uniformly splits the single laser beam into two beams in the horizontal direction, outputting two symmetrically distributed laser beams that propagate in the horizontal direction. Secondly, the two reflecting prisms... Mirrors 12 are symmetrically arranged on the left and right sides of the central beam splitter 11. These two reflecting prisms receive the two horizontal laser beams mentioned above. The function of the reflecting prisms 12 is to change the direction of light propagation and reflect the incident horizontal laser beam into a vertically downward propagating laser beam. After reflection, two parallel vertical laser beams are formed. Finally, two beam splitters 13 are located directly below the two reflecting prisms 12, forming two sets of structures corresponding to each other. Each beam splitter prism 13 is responsible for receiving a vertical laser beam from the upper reflecting prism 12 and splitting the vertical laser beam a second time.

[0023] Through the three-stage optical transformation of central beam splitting, vertical reflection on both sides, and further beam splitting below, beam splitting module 1 finally converts a single incident laser beam into four sub-beams. These four sub-beams remain parallel to each other and are arranged in a 2×2 array in space, thus providing a standard beam array layout for subsequent multi-beam parallel processing.

[0024] Preferably, the central beam splitter 11 is an isosceles right-angled triangular prism with its right-angled face facing the incident laser and its two inclined faces facing the reflecting prisms 12 on both sides. The right-angled face of the central beam splitter 11 serves as the beam incident interface, facing the direction of the incident laser, and is used to receive a single beam of laser. Its two 45-degree inclined faces serve as the output or reflection surfaces of the beam, facing the left and right sides in the horizontal direction, respectively, forming a corresponding spatial orientation relationship with the reflecting prisms 12 arranged on both sides. Both reflecting prisms 12 are isosceles right-angled triangular prisms, with their inclined surfaces facing the two inclined surfaces of the central beam splitter prism 11, and their right-angled surfaces facing the beam splitter prism 13 below. The two reflecting prisms 12 are arranged symmetrically, and their spatial orientation closely matches that of the central beam splitter prism 11. Specifically, the inclined surfaces of the reflecting prisms 12 serve as beam receiving surfaces, facing the two inclined surfaces of the central beam splitter prism 11, to receive the horizontal laser light from the central beam splitter prism 11; at the same time, the right-angled surfaces of the reflecting prisms 12 serve as beam emitting surfaces, facing downwards, directly opposite the beam splitter prism 13 below, to guide the beam in a vertical direction.

[0025] By defining both the central beam splitter prism 11 and the reflecting prism 12 as isosceles right-angled triangular prisms, and strictly defining the orientation of the right-angled surface and the inclined surface in the optical path, that is, the right-angled surface of the central beam splitter prism 11 is incident and the inclined surface faces to both sides, while the inclined surface of the reflecting prism 12 faces the center and the right-angled surface faces downward, a fully symmetrical geometric optical path structure is constructed. This specific shape and orientation combination ensures the stability of the beam propagation angle at the prism interface and ensures the accuracy of beam turning.

[0026] Preferably, the beam splitting module 1 further includes a first focusing unit 14 disposed below the two beam splitting prisms 13, used to focus and output the split sub-beams; the collimating unit 21 includes two collimating lenses 211, which respectively receive the left and right sets of sub-beams; the second focusing unit 23 includes two focusing lenses 231, which respectively focus the two sets of shaped laser beams onto the processing surface. In the structure of the beam splitting module 1, in addition to the beam splitting prisms 13, the first focusing units 14 are added. In terms of spatial layout, the two first focusing units 14 are disposed below the two beam splitting prisms 13, and their function is to receive the beams split by the beam splitting prisms. The second focusing unit 23 is specifically composed of two collimating mirrors 211, which are matched with the spatial distribution of the beam and respectively receive the left and right sets of sub-beams output from the beam splitting module to collimate the beam. The second focusing unit 23 is specifically composed of two focusing mirrors 231, which are respectively set at the end of the corresponding optical path. Their function is to focus the two sets of irregularly shaped lasers after being processed by the shaping module, and finally accurately converge the beams onto the processing surface.

[0027] Figures 6-9As an optional embodiment, the rotating graded shaping unit 22 includes three coaxially arranged shaping disks 221, each of which can rotate independently, namely the first shaping disk 2211, the second shaping disk 2212, and the third shaping disk 2213. Each of these three shaping disks 221 has an independent degree of rotational freedom, which means that the first shaping disk 2211, the second shaping disk 2212, and the third shaping disk 2213 can all rotate independently around the axis without interfering with each other, thereby flexibly adjusting their respective hole angles. The irregular holes 2221 distributed on each shaping disk 221 are of different types. This differentiated design provides a basis for selecting a variety of irregular light spots through the switching of different levels.

[0028] Figure 7 , Figure 8 As an optional embodiment, multiple sets of holes on each shaping disk 221 are evenly spaced along a circumference of the same radius with equal central angles. The central angle interval between adjacent sets of holes is 45°. A total of 8 sets of holes are provided on the entire disk, that is, the radial distance of all sets of holes from the center of the shaping disk 221 is consistent. In terms of angular distribution, these sets of holes are evenly spaced along the circumference with equal central angles. Based on the 45° equal interval distribution feature and the complete angle of 360° of the circumference, a total of 8 sets of holes are provided in the entire circle of each shaping disk 221. This specific distribution structure ensures the uniform symmetry of the holes in the circumferential direction, providing a definite spatial geometric basis for the graded positioning of the beam.

[0029] Preferably, the sub-beams are divided into left and right groups. The first group of sub-beams corresponds to the hole group in the first angular direction on the shaping disk 221, and the second group of sub-beams corresponds to the hole group in the second angular direction, which is 180° different from the first angular direction. Each group of holes includes two through holes 222 arranged coaxially in the radial direction, which correspond to the optical axis positions of the two sub-beams respectively. The sub-beams entering the laser shaping module 2 are clearly divided into left and right groups in spatial layout. Regarding the angular projection position of the beams on the shaping disk 221, the first group of sub-beams corresponds to the hole group in the first angular direction on the shaping disk 221. In contrast, the second group of sub-beams corresponds to the hole group in the second angular direction, which is 180° different from the first angular direction. This 180° difference configuration ensures that the irradiation positions of the left and right groups of sub-beams on the shaping disk are centrally symmetrically distributed.

[0030] Regarding the internal structure of each group of apertures, each group of apertures is not a single aperture structure, but contains two through holes 222. These two through holes are arranged in a specific geometric pattern on the disk surface, that is, they are arranged coaxially along the radial direction of the shaping disk 221. This arrangement is to precisely match the spatial distribution of the beams, so that the two through holes 222 correspond one-to-one with the optical axis positions of the two sub-beams in the group, thereby ensuring that the two beams can pass through the corresponding apertures simultaneously without obstruction.

[0031] Figures 7-9 As an optional embodiment, the aperture D2 of the light-transmitting hole 2222 and the circumscribed circle diameter D1 of the irregular hole 2221 satisfy D2≥1.5×D1, where D1 is the circumscribed circle diameter of the irregular hole 2221. Since the irregular hole 2221 may have a non-circular irregular contour, its circumscribed circle diameter represents the maximum spatial range of the irregular hole contour. D2 is the aperture of the light-transmitting hole 2222, that is, the diameter of its circular opening. The numerical relationship between the two is D2≥1.5×D1, that is, the diameter of the light-transmitting hole 2222 must be at least 1.5 times the maximum circumscribed circle diameter of the irregular hole 2221.

[0032] Based on the aforementioned dimensional constraints, from a physical and geometric perspective, this design ensures that the opening space of the light-transmitting aperture 2222 is much larger than the maximum cross-sectional area of ​​the beam after being shaped by the irregular aperture 2221. This dimensional difference ensures that when the irregular aperture 2221 is in working condition and has shaped a beam of a specific shape, the beam has sufficient margin when passing through the light-transmitting aperture 2222 on other levels of shaping disks, achieving complete geometric clearance, thereby avoiding any physical interference or trimming of the beam edge by the aperture wall.

[0033] As an optional embodiment, it also includes a control system 3, which includes three independent drive mechanisms 31 and a motion controller 32. These are not specifically shown in the figure of this embodiment. The three independent drive mechanisms 31 are respectively connected to the first shaping disk 2211, the second shaping disk 2212 and the third shaping disk 2213 in a one-to-one transmission connection. This design ensures that each layer of shaping disk has an independent power source and can be controlled individually. The motion controller 32 is responsible for overall command. Within the same control cycle, the motion controller 32 synchronously issues switching commands to the three sets of drive mechanisms 31. The three sets of drive mechanisms 31 work together to drive the three-layer shaping disks, namely the first shaping disk 2211, the second shaping disk 2212, and the third shaping disk 2213, to rotate according to the synchronous motion curve. The synchronous motion curve control method ensures the consistency of the three-layer shaping disks during rotation. When the first shaping disk 2211, the second shaping disk 2212, and the third shaping disk 2213 simultaneously reach their respective target angles, and the position deviations of the three-layer shaping disks are all less than a preset threshold, a state switch is triggered. The preset threshold is determined comprehensively based on the positioning accuracy of the drive mechanism, the mechanical tolerance of the shaping disk, and the processing requirements. Those skilled in the art can reasonably set it according to parameters such as the actual motor step angle and transmission clearance. For example, the preset threshold can be set to an angle position deviation ≤ 0.5°.

[0034] Figure 7As an optional embodiment, the shape of the irregular hole 2221 includes at least one of triangle, square, rhombus, hexagon, ellipse, strip or ring. The actual shape of the irregular hole 2221 can be selected from any one of the seven shapes listed above, or a combination of multiple shapes can be used as needed, providing multiple geometric basis for the shaping of the laser beam.

[0035] As an optional embodiment, the number of layers in the rotating graded shaping unit 22 is not limited to two, three, or four layers. It can be expanded to N layers according to actual process requirements, where N≥2 (not shown in the attached figure). In any working state, only one shaping disk 221 serves as the working layer to perform irregular shape shaping, while the remaining N-1 layers serve as yielding layers with light passing through the light-transmitting holes 2222. The exclusive yielding logic and switching mechanism between each layer remain unchanged. Increasing the number of layers only requires correspondingly increasing the number of channels in the drive mechanism 31 and updating the synchronous motion curve parameters of the motion controller 32. The optical principle and mechanical structure do not require substantial changes. This multi-layer expansion compatibility stems from the core size constraint that the aperture of the light-transmitting hole 2222 is larger than the outer circle diameter of all irregular holes 2221. This size constraint is decoupled from the number of layers, which can support flexible expansion of the number of layers without introducing additional geometric occlusion and diffraction.

[0036] Each shaping disk 221 has multiple sets of holes spaced along the same radius of the circumference. Each set of holes has at least one through hole 222. The through hole 222 is either an irregular hole 2221 or a light-transmitting hole 2222. The diameter of the light-transmitting hole 2222 is larger than the outer circle diameter of all the irregular holes 2221. By independently rotating each layer of shaping disk 221, the target irregular hole 2221 group on any layer is aligned with the corresponding sub-beam, and the corresponding light-transmitting hole 2222 groups on the other three layers are aligned with the sub-beam. Only the irregular holes 2221 of the working layer perform shaping modulation on the sub-beam, and four different shapes of irregular lasers are switched online. The control system 3 includes four sets of independent drive mechanisms 31 and a motion controller 32. The four sets of drive mechanisms 31 are respectively connected to the four layers of shaping disk 221 in a one-to-one transmission. The motion controller 32 sends switching commands to the four sets of drive mechanisms 31 synchronously in the same control cycle. The state switching is triggered only when the four layers of shaping disk 221 reach the target angle at the same time and the position deviation is less than the preset threshold.

[0037] As an optional embodiment, the rotating graded shaping unit 22 includes four coaxially arranged shaping disks 221, each of which can rotate independently. These are the first shaping disk, the second shaping disk, the third shaping disk, and the fourth shaping disk. The irregular holes 2221 distributed on each shaping disk 221 are of different types, which can provide four different series of irregular light spots.

[0038] By independently rotating the two shaping disks 221, in any working state, the target irregular hole 2221 group on one shaping disk is aligned with the corresponding sub-beam, and the light-transmitting hole 2222 group at the corresponding position on the other shaping disk is aligned with the sub-beam. Only the irregular hole 2221 of the current working layer performs shaping modulation on the sub-beam. When switching, the original working layer rotates to make way for the light-transmitting hole 2222, and the target working layer rotates to align the irregular hole 2221 with the beam. Two different shapes of irregular lasers can be switched online. The synchronous control logic of the two shaping disks is the same as that of the three layers. The control system 3 includes two sets of independent drive mechanisms 31 and a motion controller 32. The two sets of drive mechanisms 31 are respectively connected to the two shaping disks 221 in a one-to-one transmission. The motion controller 32 synchronously manages the positioning and interlocking of the two shaping disks in the same control cycle.

[0039] As an optional embodiment, the rotary grading shaping unit 22 includes two coaxially arranged shaping disks 221, each of which can rotate independently, namely a first shaping disk and a second shaping disk. Each shaping disk 221 has multiple sets of holes spaced apart along the same radius of the circumference. Each set of holes has at least one through hole 222. The through hole 222 is an irregular hole 2221 or a light-transmitting hole 2222. The diameter of the light-transmitting hole 2222 is larger than the outer circle diameter of all irregular holes 2221. The irregular holes 2221 distributed on the first shaping disk and the second shaping disk are of different types.

[0040] Finally, it should be noted that the methods and devices described in detail above are merely embodiments, and those skilled in the art can modify these embodiments in different ways as long as they do not depart from the scope of the present invention.

Claims

1. A multi-beam shaped laser cladding head based on a stepped shaping disc, characterized in that: include, The beam splitting module (1) splits a single incident laser beam into multiple sub-beams; The laser shaping module (2) includes a collimation unit (21), a rotational grading shaping unit (22), and a second focusing unit (23) arranged sequentially along the optical path. The rotating graded shaping unit (22) includes at least two coaxial and independently rotating shaping disks (221). Each shaping disk (221) has multiple sets of holes spaced along the circumference. Each set of holes has at least one through hole (222). The through hole (222) is either a shaped hole (2221) or a light-transmitting hole (2222). The diameter of the light-transmitting hole (2222) is larger than the outer circle diameter of the shaped hole (2221). By independently rotating the shaping disks (221) of each layer, the target irregular hole (2221) group on any layer is aligned with the corresponding sub-beam, and the light-transmitting hole (2222) group at the corresponding position of the other layers is aligned with the sub-beam. Only the irregular hole (2221) of the working layer performs shaping modulation on the sub-beam, and the output of irregular lasers of different shapes is switched online.

2. The multi-beam shaped laser cladding head based on a hierarchical shaping disc according to claim 1, characterized in that: The beam splitting module (1) includes a central beam splitting prism (11) disposed on the incident optical axis, which splits a single incident laser beam into two symmetrical horizontal laser beams; two reflecting prisms (12) symmetrically disposed on both sides of the central beam splitting prism (11), which reflect the two horizontal laser beams into two parallel vertical laser beams respectively; and two beam splitting prisms (13) disposed below the two reflecting prisms (12), which split the two vertical laser beams into four sub-beams that are parallel to each other and arranged in a 2×2 array.

3. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 2, characterized in that: The central beam splitter (11) is an isosceles right-angled triangular prism with its right-angled face facing the incident laser and its two inclined faces facing the reflecting prisms (12) on both sides respectively. Both reflecting prisms (12) are isosceles right-angled triangular prisms, with their inclined surfaces facing the two inclined surfaces of the central beam splitter (11) respectively, and their right-angled surfaces facing the beam splitter (13) below.

4. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 1, characterized in that: The rotating graded shaping unit (22) includes three layers of coaxially arranged shaping disks (221) that can rotate independently, namely the first shaping disk (2211), the second shaping disk (2212) and the third shaping disk (2213), and the irregular holes (2221) distributed on each layer of shaping disk (221) are of different types.

5. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 1, characterized in that: Multiple sets of holes on each shaping plate (221) are evenly distributed along the same radius of the circumference with equal central angles. The central angle interval between adjacent sets of holes is 45°. A total of 8 sets of holes are provided on the entire plate.

6. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 1, characterized in that: The sub-beams are divided into two groups, left and right. The first group of sub-beams corresponds to the hole group in the first angular direction on the shaping disk (221), and the second group of sub-beams corresponds to the hole group in the second angular direction which is 180° different from the first angular direction. Each group of holes includes two through holes (222) arranged coaxially in the radial direction, which correspond to the optical axis positions of a group of two sub-beams respectively.

7. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 1, characterized in that: The aperture D2 of the light-transmitting hole (2222) and the circumscribed circle diameter D1 of the irregular hole (2221) satisfy D2≥1.5×D1.

8. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 4, characterized in that: It also includes a control system (3), which includes three independent drive mechanisms (31) and a motion controller (32). The three independent drive mechanisms (31) are respectively connected to the first shaping disk (2211), the second shaping disk (2212) and the third shaping disk (2213) in a one-to-one transmission connection. The motion controller (32) synchronously sends switching commands to the three sets of drive mechanisms (31) within the same control cycle, driving the three-layer shaping disk (221) to rotate according to the synchronous motion curve; the state switching is triggered only when the three-layer shaping disk (221) reaches the target angle at the same time and the position deviation is less than the preset threshold.

9. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 1, characterized in that: The shape of the irregular hole (2221) includes at least one of the following: triangle, square, rhombus, hexagon, ellipse, strip, or ring.

10. The multi-beam irregular-shaped laser cladding head based on a graded shaping disk according to claim 2, characterized in that: The beam splitting module (1) also includes a first focusing unit (14) disposed below the two beam splitting prisms (13) respectively, for focusing the split sub-beams for output; the collimation unit (21) includes two collimating lenses (211) respectively receiving the left and right sub-beams; the second focusing unit (23) includes two focusing lenses (231) respectively focusing the two shaped laser beams onto the processing surface.

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