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 creation of perforations in materials used in aerospace production.
Innovation Solution
A perforation system comprising a laser system with an optical beamlet generator and a scanner that simultaneously directs and moves beamlets in orthogonal dimensions, utilizing a lenslet array or diffractive optical element to create two-dimensional perforations on a substrate, with a movable base allowing for alignment and configuration of multiple optical beamlet generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a galvo-based x-y scanner is used to control 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 patent divides a single laser beam into multiple beamlets using a beamlet generator (such as a microlens array or diffractive optical element). Each beamlet can be independently directed to different locations on the substrate, allowing parallel processing of multiple perforation points simultaneously, thereby dramatically increasing productivity while maintaining control flexibility
Solution Approach 2:
The patent introduces a temporal dimension to the scanning process by rapidly switching between multiple beamlets in sequence. This allows the system to cover a two-dimensional area with the equivalent speed of a single beam, effectively adding a time-based dimension to the scanning approach that resolves the speed-flexibility contradiction
2Device complexity
If a single laser beam is used with traditional scanning, then the system configuration is simpler, but the time required to form multiple perforations is longer
Solution Approach 1:
The patent segments the laser beam into multiple beamlets using compact optical components such as microlens arrays or diffractive optical elements. These components can be integrated into the existing laser scanner housing, adding multi-beam functionality without substantially increasing overall system complexity or footprint
Solution Approach 2:
The patent introduces a beamlet generator as an intermediary component between the laser source and the scanning mirrors. This intermediary device rapidly switches between multiple beamlets, enabling parallel perforation creation while maintaining compatibility with existing scanner architectures, thus minimizing the increase in system complexity
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 configuration significantly enhances the speed and efficiency of perforation creation, reducing the time required to form multiple perforations compared to standard systems, particularly beneficial for large-scale aerospace applications.
Implementation Method 1
The optical beamlet generator may be in the form of a lenslet array or a diffractive optical element
Implementation Method 2
The optical beamlet generator may be in the form of a lenslet array or a diffractive optical element
Implementation Method 3
The scanner (e.g., at least a first movable mirror and a second movable mirror) is configured to simultaneously direct beamlets from the optical beamlet generator toward a substrate and to simultaneously move the plurality of beamlets relative to the substrate in first and second dimensions that are orthogonal to one another
Implementation Method 4
A perforation system may include a laser system and a scanner. The laser system may include a laser and an optical beamlet generator
Implementation Method 5
each beamlet defines a two-dimensional perforation on a surface of the substrate through operation of the scanner
Data Source
AI summary
A perforation system is disclosed that utilizes an optical beamlet generator and a scanner (e.g., at least two moveable mirrors). 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. These beamlets are moved in at least two dimensions relative to a surface of a substrate to form perforations in the substrate.