Backstrike Detection in Laser Drilling Thin Materials
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Solution Overview
Problem
Existing methods fail to detect backstrikes during laser drilling of thin materials, which can cause damage to adjacent materials due to geometric or material constraints, making visual inspection impossible and resulting in undetectable damage until the assembly is dismantled.
Innovation Solution
A drill and detection system comprising a laser drill and a thermal detector, with a processor and actuator, that monitors temperature changes in adjacent materials to detect backstrikes and automatically adjust or stop the drilling process to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser drilling is performed on thin materials without detection systems, then drilling speed and productivity are improved, but backstrikes occur causing damage to adjacent materials
Solution Approach 1:
The thermal detector continuously monitors temperature changes in the second thin material and provides real-time feedback to the control system. When a temperature increase indicating a backstrike is detected, the system automatically adjusts or stops the laser drilling process to prevent damage, while maintaining high productivity through automated control.
Solution Approach 2:
A thermal detector is introduced as an intermediary device between the laser drill and the second thin material. This detector monitors thermal changes in the second material caused by backstrikes and transmits signals to the control system, enabling indirect detection and prevention of damage without interfering with the drilling process.
2Reliability
If visual inspection methods are used to detect backstrikes, then detection capability is improved, but geometric or material constraints make inspection impossible
Solution Approach 1:
The patent replaces visual inspection methods with a thermal detection system. Instead of requiring physical access to view color changes or inspect between materials, the thermal detector uses thermal radiation detection to monitor temperature changes in the second material, overcoming geometric and material constraints that prevent visual inspection.
Solution Approach 2:
The thermal detector serves as an intermediary that indirectly detects backstrikes by monitoring thermal changes in the second material. This eliminates the need for direct visual access to the drilling site or color change observation, allowing detection in geometrically constrained or opaque material configurations.
3Measurement precision
If thermal detectors are positioned close to the laser drill for monitoring, then detection sensitivity is improved, but the detection system complexity increases
Solution Approach 1:
The control system integrates multiple functions into a single unit: it receives signals from the thermal detector, processes temperature data, determines when backstrikes have occurred, and automatically adjusts or stops the laser drilling process. This multi-functionality reduces overall system complexity despite the close positioning of components.
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 non-invasive detection and prevention of backstrikes, reducing material damage by allowing real-time monitoring and automatic intervention during the drilling process.
Implementation Method 1
monitoring a second thin material proximate the first thin material with a thermal detector... detecting a change in temperature in the second thin material with the thermal detector
Data Source
AI summary
In accordance with one aspect of the disclosure, a drill and detection system is disclosed. The system may include a drill and a thermal detector spaced apart from the drill. The drill may be directed in a first direction and the thermal detector may be directed in a second direction opposite the first direction.