Energy Beam Scan Supervision Using Mirror Encoder Feedback
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Solution Overview
Problem
Current scanner technologies for energy beam processing, such as laser systems, often fail to maintain the predetermined scanning pattern due to limitations like mirror weight, inertia, and rotation speed, leading to anomalous scans that can result in incorrect processing and safety hazards.
Innovation Solution
A method and system that utilize encoders to measure and compare the actual scanning pattern with a predetermined threshold area, determining if the scan is anomalous and potentially stopping the apparatus to prevent damage and ensure quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the scanner operates at high speeds with heavy mirrors to meet demanding scanning conditions, then the scanning speed and power are improved, but the manufacturing precision and reliability deteriorate due to inertia and inability to follow predetermined patterns
Solution Approach 1:
The system continuously measures the actual positions of the mirrors using encoders during scanning operation, compares the actual scanning pattern with the predetermined scanning pattern, and uses this feedback information to detect deviations. This real-time feedback mechanism enables the system to monitor and identify scanning inaccuracies caused by mirror inertia and high-speed operation limitations.
Solution Approach 2:
The patent replaces direct mechanical control reliance with an optical/electronic measurement system. Instead of depending solely on mechanical precision of mirror positioning, the system uses encoders to optically/electronically measure mirror positions and computationally determine the actual scanning pattern, substituting mechanical precision requirements with measurement and computation.
2Manufacturing precision
If the scanner is designed with lighter mirrors to improve scanning precision and responsiveness, then the manufacturing precision is improved, but the productivity decreases due to inability to maintain high-speed scanning
Solution Approach 1:
The feedback system measures actual mirror positions during high-speed scanning and computationally determines the actual scanning pattern. This allows the system to maintain high-speed operation with lighter mirrors while detecting and accounting for any deviations from the predetermined pattern, enabling both speed and precision to be achieved through measurement and monitoring rather than purely mechanical design.
3Productivity
If the scanner operates at maximum capacity to meet production demands, then the productivity is improved, but the reliability deteriorates due to anomalous operation and potential mirror failure
Solution Approach 1:
The system continuously monitors mirror positions and actual scanning patterns during high-capacity operation. By comparing actual patterns with predetermined patterns, the feedback mechanism detects anomalous operation early, allowing for preventive measures before mirror failure occurs, thus maintaining reliability during high-productivity operation.
Solution Approach 2:
The monitoring system provides early warning of anomalous operation before actual failure occurs. By detecting deviations in the actual scanning pattern from the predetermined pattern, the system can take preventive actions (such as adjusting operation parameters or stopping before failure) to cushion against potential mirror breakage during high-capacity operation.
4Manufacturing precision
If the scanner follows the predetermined scanning pattern exactly to ensure processing quality, then the manufacturing precision is improved, but the device complexity increases due to additional monitoring and control systems
Solution Approach 1:
The system uses relatively simple encoder devices to measure mirror positions and computationally determines the actual scanning pattern through processing these measurements. This feedback approach provides comprehensive monitoring of scanning accuracy without requiring complex additional hardware, achieving high manufacturing precision through intelligent processing of basic position data.
Solution Approach 2:
The system creates a digital copy of the actual scanning pattern by computationally determining positions from encoder measurements. This digital representation of the actual scanning path allows for easy comparison with the predetermined pattern without requiring complex physical measurement devices, simplifying the monitoring system while maintaining precision.
Data Source
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AI summary
A method for supervision of a scan of an energy beam, is disclosed. The method comprises providing an apparatus configured to provide the energy beam; providing a scanner configured to scan the energy beam, the scanner comprising a first mirror and a second mirror; operating the apparatus and the scanner such that the energy beam is provided while it is scanned according to a predetermined scanning pattern; determining, at least one processor of a computer device or system, an actual scanning pattern of the energy beam, when both the apparatus and the scanner are operated, by processing measurements provided by encoders of the first mirror and the second mirror; and comparing, the at least one processor, the actual scanning pattern with a predetermined threshold area. A system for supervision of a scan of an energy beam, is also disclosed. The system comprises an apparatus configured to provide the energy beam; a scanner configured to scan the laser beam, the scanner comprising a first mirror and a second mirror, each mirror comprising at least an encoder, the scanner and the apparatus being configured to provide the energy beam while it is scanned according to a predetermined scanning pattern; and a computing device or system comprising at least one processor. A computer program product is also disclosed. A data stream which is representative of such a computer program product, is also disclosed.