Adaptive Laser Toolpaths for Accurate Texture and Cavity Machining
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Solution Overview
Problem
Existing laser machining methods for engraving textures or cavities on workpieces suffer from inaccuracies in depth and planarity due to layer-by-layer machining, with no real-time adjustment capabilities to correct errors during the process.
Innovation Solution
A method and apparatus for laser machining that involves calculating an initial machining path based on workpiece geometry and texture/cavity, adjusting the path in real-time by scanning and measuring the machined surface, and recalculating the path to correct deviations, allowing for adaptive machining to improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the machining path is fixed before machining, then the machining process is simple to control, but no real-time correction of depth deviations is possible
Solution Approach 1:
The system incorporates real-time feedback through surface scanning and measurement after each layer, allowing the control unit to detect depth deviations and automatically adjust the machining path for subsequent layers. This maintains operational simplicity while enabling dynamic correction of depth accuracy issues.
2Length of moving object
If multiple layers are machined to achieve deep cavities, then the maximum machining depth is increased, but error accumulation reduces the final machining accuracy
Solution Approach 1:
By implementing feedback through surface scanning after each layer and dynamically adjusting the machining path based on measured deviations, the system prevents error accumulation even when machining multiple deep layers. Each layer's actual depth is used to correct the path for the next layer, maintaining accuracy throughout the entire depth range.
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
Enables real-time correction of geometrical inaccuracies during machining, enhancing the precision and quality of engraved textures or cavities by compensating for errors as they occur, thus improving the final machined surface topology.
Implementation Method 1
Laser ablation methods are widely used for engraving a texture on the surface of a physical object by sublimating the material on the surface of the object
Implementation Method 2
scanning a defined machined area on the surface of the workpiece by a measuring device to obtain the machined depths at a plurality of positions on the machined area
Data Source
Figure 1~5
Figure 6~8b
Figure 9a~14
AI summary
The present invention is related to a laser machining method for engraving a texture or a cavity on a workpiece (5) by a machine tool, wherein the machine tool includes a machine table for mounting the workpiece (5) thereon and a laser head for emitting a laser beam on the workpiece (5), wherein the laser beam is directed by a laser galvo scanner integrated in the laser head to reach a defined position on the workpiece (5), wherein the machine tool further comprises a control unit configured to control the movement of the laser head and the laser galvo scanner. The method comprises: a. calculating before machining a machining path based on the geometry of the workpiece (5) and the texture or the cavity, wherein the machining path defines a sequence of relative positions of the laser head in relation to the workpiece (5), wherein calculating the machining path includes the steps of calculating a plurality of machining layers to be machined in succession and calculating for each layer a plurality of laser toolpaths defining the positions to be ablated by the laser beam; b. receiving the machining path by the control unit for ablating the workpiece; c. ablating the workpiece (5) layer by layer; d. adjusting the machining path after machining at least one layer including: i. scanning a defined machined area on the surface of the workpiece (5) by a measuring device to obtain the machined depth at a plurality of positions on the machined area; ii. comparing the measured machined depth with a defined target depth at the plurality of positions on the machined area to determine depth deviation; and iii. recalculating at least partially the machining path based on the determined depth deviation; and e. applying the recalculated machining path to ablate the remaining layers of the workpiece (5).