Beam Imaging Sensor with Segmented Aperture for High-Power Density
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Solution Overview
Problem
Existing beam imaging sensors face challenges in reliably measuring power density distribution of high-power electron or ion beams, particularly at energy levels above 5 kW, due to thermal load issues and limitations in repeatability and accuracy.
Innovation Solution
A beam imaging sensor design featuring a circumferential slit formed by nesting inner and outer slit discs, which allows for precise measurement of beam power density distribution by minimizing thermal load and maintaining accuracy across varying beam energies, using a Faraday cup and conductive leads to detect and analyze the beam's electrical signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art beam imaging sensors are used to measure power density distribution, then measurement capability is provided, but thermal load causes sensor failure at energy levels above 5 kW
Solution Approach 1:
The sensor aperture is divided into multiple discrete zones (first aperture zone, second aperture zone, third aperture zone) that can independently sample different portions of the beam. This segmentation allows the beam energy to be distributed across multiple sampling points rather than concentrated on a single point, reducing thermal load on any individual sensor component while maintaining measurement capability.
Solution Approach 2:
The patent transitions from conventional single-point or linear scanning measurement approaches to a multi-zonal aperture sampling approach that effectively adds spatial dimensionality to the measurement process. Multiple aperture zones sample different radial portions of the beam simultaneously or sequentially, enabling power density distribution measurement while distributing thermal exposure across multiple locations.
2Measurement precision
If conventional beam imaging sensors are used, then basic measurement function is provided, but measurement precision and accuracy are insufficient for high-power beams
Solution Approach 1:
The beam cross-section is divided into multiple measurement zones through the aperture segmentation, allowing independent measurement of power density at different radial positions. This enables reconstruction of the complete power density distribution profile with higher precision than single-point measurements, while each individual zone experiences reduced thermal load.
Solution Approach 2:
The patent replaces direct mechanical/physical beam interaction at a single point with an electromagnetic field-based sampling approach through multiple aperture zones. The electric field distribution is sampled across multiple zones to reconstruct power density, reducing reliance on thermal-mechanical sensor responses that fail under high thermal load.
3Adaptability or versatility
If single-aperture sensors are used, then simple structure is maintained, but inability to handle high energy levels limits applicability
Solution Approach 1:
The sensor incorporates multiple aperture zones (first, second, and third aperture zones) with different dimensions and positions, enabling the sensor to handle high energy levels by distributing beam sampling across multiple zones. Each zone can be optimized for specific energy ranges, increasing overall adaptability while the modular segmented structure manages complexity.
Solution Approach 2:
The multi-zonal aperture design provides universal measurement capability across a wide range of beam energy levels (from low-power research beams to high-power industrial beams exceeding 5 kW). The same sensor structure can measure different power density distributions by utilizing different combinations of aperture zones, making it adaptable to various application scenarios.
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
The sensor effectively measures and reconstructs the power density distribution of high-power beams with enhanced accuracy and reliability, capable of handling energy levels exceeding 30 kW, thereby improving weld quality and consistency across different machines and operators.
Implementation Method 1
a Faraday cup located within the at least one channel, the Faraday cup being positioned to receive at least a portion of an electron, or ion, beam
Implementation Method 2
at least one conductive lead in electrical communication with the Faraday cup, the at least one conductive lead being able to conduct an electrical signal generated by the portion of the beam that comes into contact with the Faraday cup
Data Source
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AI summary
The present invention relates generally to the field of sensors for beam imaging and, in particular, to a new and useful beam imaging sensor for use in determining, for example, the power density distribution of a beam including, but not limited to, an electron beam or an ion beam. In one embodiment, the beam imaging sensor of the present invention comprises, among other items, a circumferential slit that is either circular, elliptical or polygonal in nature.