Laser Beamlet Perforation Scanning for Faster Aerostructure Drilling
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Solution Overview
Problem
Existing laser/scanner perforation systems for aerostructures are slow due to the limitations of galvo-based x-y scanners, which hinder efficient production in aerospace applications.
Innovation Solution
A perforation system utilizing a movable base with multiple optical beamlet generators, such as lenslet arrays or diffractive optical elements, to generate and align beamlets for precise control over perforation formation on a substrate, allowing for faster and more flexible creation of perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a galvo-based x-y scanner is used to control laser beam direction, then flexible pointing control in two planes is achieved, but the process speed for creating perforations becomes relatively slow
Solution Approach 1:
The invention segments the laser beam into multiple parallel beamlets using a beamlet generator (such as a diffractive optical element or lenslet array). This allows simultaneous processing of multiple locations on the substrate, thereby increasing overall perforation speed while maintaining control flexibility through the scanner.
Solution Approach 2:
The invention transitions from controlling a single laser beam in two dimensions (x-y scanner) to controlling multiple beamlets in three dimensions by adding the spatial dimension of parallel beam propagation. This enables simultaneous multi-point processing, resolving the speed limitation while preserving scanning flexibility.
2Adaptability or versatility
If a standard two galvanometer mirror system is used, then adequate control for many applications is achieved, but the process becomes slow for aerostructure production
Solution Approach 1:
The invention merges the advantages of both approaches by combining the versatility of the galvo-based scanner with the speed enhancement of parallel beamlet processing. The beamlet generator is integrated into the existing scanner system, allowing it to maintain adaptability across applications while dramatically improving productivity for aerostructure production.
Solution Approach 2:
The beamlet generator can be configured with different numbers and arrangements of beamlets, allowing the system to adapt to various production requirements while consistently delivering high-speed performance. This multi-functionality enables the system to serve both general applications and specialized aerostructure production needs.
3Power
If multiple lasers are used in conjunction with a galvo-based scanner, then perforation capability is enhanced, but system complexity increases
Solution Approach 1:
Instead of using multiple physical lasers, the invention creates multiple virtual lasers by generating beamlets from a single laser source through a beamlet generator. This achieves the power and multi-point capability of multiple lasers while avoiding the complexity of synchronizing and controlling multiple independent laser systems.
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
This approach significantly reduces the time required to form perforations compared to standard systems, enhancing production efficiency, especially for large surfaces and complex perforation patterns.
Implementation Method 1
a laser generates and outputs light along an optical path
Implementation Method 2
said optical beamlet generator comprises a lenslet array... said lenslet array generates and outputs said plurality of beamlets
Implementation Method 3
said optical beamlet generator comprises a diffractive optical element... said diffractive optical element generates and outputs said plurality of beamlets
Implementation Method 4
said first movable mirror controls an impact location of said plurality of beamlets on the substrate in said first dimension
Implementation Method 5
said second movable mirror controls an impact location of said plurality of beamlets on the substrate in said second dimension
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A
AI summary
A perforation system (100) is disclosed that utilizes an optical beamlet generator and a scanner (190), e.g., at least two moveable mirrors 150). The optical beamlet generator may be a lenslet array or a diffractive optical element. The optical beamlet generator outputs a plurality of beamlets from a single input laser beam (122). These beamlets are moved in at least two dimensions relative to a surface (22) of a substrate (20) to form perforations in the substrate (20).