3D Laser Batch Processing with Tessellation and Dynamic Focusing
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Solution Overview
Problem
Current laser processing technologies are inefficient for treating batches of identical 3D-shaped objects due to limitations in precision, positioning speed, and cost-effectiveness, particularly in achieving perpendicular laser beam incidence and maintaining energy density on complex surfaces.
Innovation Solution
A method and system utilizing a laser processing machine with at least eight degrees of freedom for positioning a focused laser beam, involving tessellation of 3D objects into segments, dynamic focusing, and optimized platform orientation to minimize repositioning and ensure perpendicular beam incidence, enabling fast and efficient batch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a robotic arm is used for 3D laser processing, then flexibility in processing freeform objects is improved, but positioning precision and speed deteriorate
Solution Approach 1:
The system divides the positioning function into two independent parts: a robotic arm for coarse positioning and a galvanometer scanner for fine positioning. This segmentation allows each component to optimize its function - the robotic arm provides flexibility for complex 3D positions while the galvanometer ensures high precision for laser spot placement.
Solution Approach 2:
The galvanometer scanner acts as an intermediary device between the robotic arm and the laser source. It receives commands from the control system to make rapid, precise adjustments to the laser beam direction, compensating for the limited precision of the robotic arm's positioning.
2Area of stationary object
If a gantry system with rotary and swing axes is used for 3D processing, then processing capability for large dimensions is improved, but positioning speed deteriorates due to high moving mass
Solution Approach 1:
The positioning system is segmented into slow, large-range robotic arm movements for positioning over large areas and fast, small-range galvanometer movements for rapid laser spot repositioning. This allows the system to cover large processing areas while maintaining high positioning speeds within the galvanometer's working range.
Solution Approach 2:
The system dynamically switches between two positioning modes: robotic arm positioning for changing processing areas and galvanometer positioning for rapid movements within the same area. This dynamic allocation of positioning tasks optimizes both coverage area and positioning speed.
3Productivity
If multiple laser modules are used for batch processing, then processing throughput is improved, but system cost and complexity increase
Solution Approach 1:
The system merges batch processing capability with a single laser module by combining robotic arm positioning, galvanometer scanning, and automated object handling. This integration allows multiple objects to be processed sequentially with rapid repositioning, achieving high throughput without the complexity and cost of multiple laser systems.
Solution Approach 2:
The system maintains continuous processing by rapidly repositioning the laser between objects using the galvanometer and automated platform. Objects are arranged in batches and processed in sequence without idle time, keeping the laser continuously engaged in useful work while minimizing repositioning overhead.
4Manufacturing precision
If the laser beam is tilted to match surface orientation, then energy density is improved, but system complexity increases
Solution Approach 1:
The galvanometer scanner serves as an intermediary that tilts the laser beam to match surface orientations. By placing the galvanometer in the optical path, the system achieves variable beam angles without mechanically tilting the entire laser or object, simplifying the overall mechanical complexity while maintaining energy density.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces process cycle time by optimizing the number of tessellation segments and using fast axes for laser treatment, achieving efficient and cost-effective processing of complex 3D objects with improved energy density and reduced thermal side effects.
Implementation Method 1
laser treatment of batches of identical 3D objects
Data Source
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AI summary
A method and system for batch processing of 3D objects using laser treatment includes loading a batch of 3D objects into laser processing machine on a platform designed based on symmetry of the objects, partitioning their surface into tessellations segments which size is limited by a virtual 3D working volume of a two-mirror galvoscanner and dynamic focusing unit, a laser process parameter window, and require overlap between the segments. A workflow algorithm for all 3D objects treated within a single process cycle is created by an iteration method, taking into account accessibility of the tessellation segments by the laser beam. The segments from different 3D objects fitting into the same virtual 3D working volume are merged together to reduce repositioning time. The treatment is performed according to a queue of the tessellation segments utilising fast motion of the galvoscanner and dynamic focusing unit to reduce the cycle time.