Bi-Conical Laser Reflection for Circumferential Rod Processing
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Solution Overview
Problem
Conventional laser processing of rod-shaped workpieces is limited by the speed of physical workpiece rotation, and maintaining robust contact and alignment during welding tasks, especially for small-diameter workpieces, is challenging due to the need for physical rotation.
Innovation Solution
A bi-conical reflector system is used to radially irradiate the workpiece, allowing for laser processing around its circumference without rotating the workpiece, utilizing a laser beam scanner and two conical mirror surfaces that are rotationally symmetric about the center axis to direct the laser beam radially outward and inward, enabling faster processing and maintaining robust contact during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical workpiece rotation is used to process rod-shaped workpieces, then the workpiece can be irradiated from different angles, but the processing speed is limited by the rotation speed
Solution Approach 1:
Instead of rotating the workpiece to achieve multi-angle irradiation, the patent inverts the approach by keeping the workpiece stationary and rotating the laser beam delivery system (optical assembly) around the workpiece. This allows the laser beam to approach the workpiece from different angles while the workpiece remains fixed, thereby eliminating the speed limitation imposed by workpiece rotation.
Solution Approach 2:
The patent replaces the mechanical workpiece rotation system with an optical scanning system. The optical assembly, which can rotate independently around the workpiece, delivers the laser beam to different positions and angles. This substitution eliminates the need to mechanically rotate the workpiece, enabling faster processing speeds while maintaining the capability to irradiate all surfaces of rod-shaped workpieces.
2Adaptability or versatility
If physical workpiece rotation is used for welding tasks, then different sides of the workpiece can be welded, but maintaining robust contact and alignment is challenging especially for small-diameter workpieces
Solution Approach 1:
The patent inverts the traditional welding approach by keeping the workpiece stationary in a robust fixture and rotating the optical assembly instead. This inversion allows the laser beam to access different welding positions while the workpiece maintains stable contact with the fixture, eliminating alignment challenges associated with rotating small-diameter workpieces.
Solution Approach 2:
The patent replaces the mechanical workpiece rotation and repositioning system with a rotating optical assembly. The optical assembly can deliver the laser beam to any position around the stationary workpiece, eliminating the need to physically manipulate or reposition the workpiece during welding. This significantly improves contact and alignment stability, especially for small-diameter workpieces that are difficult to handle and reposition.
3Productivity
If laser beam scanning is used instead of physical rotation, then processing speed can be increased, but a mechanism is needed to scan the laser beam around the workpiece circumference
Solution Approach 1:
The optical assembly serves multiple functions: it focuses the laser beam, positions it precisely, and can rotate around the workpiece to deliver the beam from different angles. This multi-functional design eliminates the need for separate scanning mechanisms, reducing overall system complexity while enabling high-speed processing through laser beam scanning instead of physical workpiece rotation.
Solution Approach 2:
The optical assembly acts as an intermediary between the laser source and the workpiece. It receives the laser beam from a fixed laser source and delivers it to different positions around the stationary workpiece by rotating. This intermediary approach allows the laser beam to be scanned around the workpiece circumference without requiring the workpiece itself to move, achieving high processing speeds with a relatively simple rotating optical mechanism.
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 allows for higher processing speeds and improved quality by eliminating the need for physical workpiece rotation, enhancing alignment and contact during welding, and maintaining focused laser beam parameters for efficient processing across the workpiece circumference.
Implementation Method 1
The first conical mirror surface is arranged to reflect the laser beam radially outwards onto the second conical mirror surface
Implementation Method 2
The second conical mirror surface is arranged to reflect the laser beam radially inwards onto the workpiece
Data Source
AI summary
An apparatus for radial laser processing of a workpiece, located on a center axis, includes a laser beam scanner directing a laser beam along but offset from the center axis, and a bi-conical reflector system including first and second conical mirror surfaces surrounding the center axis. The first conical mirror surface faces away from the center axis to reflect the laser beam radially outwards therefrom, toward the second conical mirror surface. The second conical mirror surface faces the center axis to reflect the laser beam radially inwards toward the workpiece. The laser beam scanner azimuthally scans a location of incidence of the laser beam on the first conical mirror surface to scan an azimuthal angle of propagation of the laser beam from the second conical mirror surface toward the workpiece. The apparatus enables irradiation of the entire circumference of the workpiece without physically rotating the workpiece.