Laser Texturing of Cylinders With Eccentricity Compensation
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Solution Overview
Problem
Existing laser texturing processes for cylindrical bodies face challenges due to potential eccentricities between the cylinder's surface and the rotation axis, leading to non-uniform processing and unacceptable quality levels.
Innovation Solution
An apparatus and process that utilize a control unit to monitor the distance between the laser emitter and the cylindrical body's surface using a distance sensor, allowing for real-time correction of eccentricities by adjusting the position of the laser emitter along the auxiliary direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the cylinder is supported between centers during laser processing, then high rotation speeds can be achieved without damaging support surfaces, but eccentricity between the rotation axis and lateral surface occurs leading to non-uniform processing
Solution Approach 1:
The patent implements a dynamic correction system where the distance between the laser head and cylinder surface is continuously monitored and adjusted during rotation. The control unit modifies the laser head position in real-time to compensate for eccentricity, allowing the system to maintain processing precision despite high rotation speeds and support-induced eccentricity.
Solution Approach 2:
The patent employs a feedback mechanism using a distance sensor to measure the actual gap between the laser head and rotating cylinder surface. This measurement is fed back to the control unit, which automatically adjusts the laser head position to maintain constant distance, thereby correcting for eccentricity caused by center-supported rotation at high speeds.
2Manufacturing precision
If the cylinder is supported at necks or shoulders during grinding, then coaxiality is maintained, but separate support means are required introducing potential eccentricity risk
Solution Approach 1:
The patent makes the laser processing support system multi-functional by enabling it to serve both as the rotation support and as the processing reference. The centers used for laser processing also function as the rotation support, eliminating the need for separate grinding supports and the complexity associated with transferring workpieces between different support systems.
Solution Approach 2:
The patent merges the function of rotation support and laser processing reference into a single support system. By using the same center support for both purposes, the system eliminates the complexity of coordinating multiple support systems and avoids the eccentricity risks associated with transferring cylinders between different support means.
3Device complexity
If laser texturing is performed with fixed head position, then device complexity is reduced, but geometric errors in cylinder shell cause variability in texturing quality
Solution Approach 1:
The patent transforms the static laser head positioning into a dynamic system that automatically adjusts its position during operation. The control unit continuously modifies the laser head location based on real-time distance measurements, enabling the system to adapt to geometric variations in the rotating cylinder shell and maintain consistent texturing quality.
Solution Approach 2:
The patent implements a feedback control loop where the distance sensor monitors the gap between laser head and cylinder surface, and the control unit uses this information to automatically adjust the laser head position. This closed-loop system compensates for geometric errors in the cylinder shell, maintaining texturing uniformity without requiring overly complex pre-positioning mechanisms.
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 solution ensures accurate and uniform laser texturing at high rotation speeds, maintaining the desired surface roughness characteristics and preventing variations in texturing depth, thereby improving the overall quality of the processed cylinder.
Implementation Method 1
a distance sensor (700) arranged in a predetermined positional relationship with respect to the laser emitter (600) and configured for detecting a control parameter relative to a distance of the sensor itself or of the laser emitter (600) from a lateral surface (2) of the cylindrical body (1)
Implementation Method 2
at least one laser emitter (600) configured for emitting at least one laser beam in the direction of said operative seat
Implementation Method 3
emitting at least one laser beam in the direction of said operative seat, thereby allowing a surface processing of the cylindrical body (1)
Data Source
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AI summary
An apparatus and relative process for the surface processing of cylindrical bodies are described, in particular for the surface texturing of rolling cylinders. The apparatus comprises a work station (100) for rotatably supporting the cylindrical body (1), a laser emitter (600) movable along a main direction (X) parallel to the rotation axis (K) of the cylindrical body (1) and according to an auxiliary direction (Z) transverse to the main direction (X), a distance sensor (700) for detecting a control parameter relative to a distance of the sensor itself or of the laser emitter (600) from an external lateral surface of the cylindrical body (1), and a control unit (15) connected with the laser emitter (600) and with the distance sensor (700). The control unit (15) is configured for commanding a movement of the laser emitter (600) and of the distance sensor (700) along said main direction (X), commanding the emission of a laser beam directed towards a surface of the cylindrical body (1), executing a correction procedure adapted to compensate for the eccentricity of the cylindrical body (1) with respect to said rotation axis (K).