Deformable Mirror Laser Beam Control for Precise Metal Processing
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Solution Overview
Problem
Laser processing machines face challenges in achieving high-speed, precise, and cost-effective operations due to the need for precise alignment of the laser beam and assist gas flow axes, which is often compromised by mechanical limitations and inertia during high-dynamic movements, leading to imperfect processing results.
Innovation Solution
The method involves controlling the transverse power distribution of the laser beam in real-time to adjust the position of the optical axis relative to the assist gas flow axis, allowing for non-coaxial alignment and dynamic adjustments during processing, using a deformable reflecting element and electronic control systems to maintain precise positioning and beam shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed laser processing is implemented, then productivity increases, but mechanical inertia causes misalignment between laser beam axis and assist gas flow axis, deteriorating manufacturing precision
Solution Approach 1:
The patent replaces mechanical adjustment systems with an optical control system. A deformable reflecting element (such as a deformable mirror) is used to dynamically adjust the laser beam path and position in real-time, substituting mechanical movement and adjustment mechanisms with optical field control. This allows precise beam positioning without mechanical inertia limitations.
Solution Approach 2:
The patent implements dynamic control of the laser beam position through real-time deformation of the reflecting element. The system continuously adapts the beam path during high-speed processing, allowing the optical system to respond dynamically to position changes without mechanical lag. This enables maintaining alignment precision even during rapid movements and complex path variations.
2Adaptability or versatility
If complex path variations are processed, then adaptability improves, but mechanical adjustments become insufficient, deteriorating manufacturing precision
Solution Approach 1:
The deformable reflecting element provides continuous, dynamic adjustment capability that can adapt to any processing path complexity. By controlling the surface shape of the reflector in real-time, the system can steer the laser beam along complex trajectories while maintaining precise positioning accuracy, overcoming the limitations of discrete mechanical adjustment mechanisms.
Solution Approach 2:
The patent changes the optical parameters of the reflecting element (surface curvature, orientation, position) dynamically during processing. By modulating these parameters in real-time based on the required processing path, the system achieves high adaptability to complex geometries while maintaining beam accuracy through optical field control rather than mechanical repositioning.
3Manufacturing precision
If real-time beam control is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The deformable reflecting element serves as an intermediary between the laser source and the workpiece. Instead of directly moving or repositioning components, the system uses the reflector as a mediating optical element to control beam position and shape. This intermediary approach simplifies the overall system architecture by centralizing control in a single adjustable component rather than requiring multiple moving parts and complex coordination 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
This approach enhances processing speed, quality, and cost-effectiveness by enabling real-time control of the laser beam's position relative to the assist gas flow, reducing the need for mechanical adjustments and maintaining precision during complex path variations, thus improving machining performance.
Implementation Method 1
a deformable reflecting element and electronic control systems to maintain precise positioning and beam shaping
Implementation Method 2
the optical focusing system 16 of the laser beam, generally consisting of a focusing lens, adapted to focus the laser beam along an optical axis of propagation incident on the metallic material
Implementation Method 3
the interaction parameters of the laser beam with the material being processed, specifically on the energy density per incidence volume of the laser beam on the material
Implementation Method 4
a high-powered focused laser beam having a predetermined transverse power distribution on at least one working plane of the metallic material
Implementation Method 5
an assist gas flow must be provided to the working region wherein the interaction between the laser beam and the material occurs which has the mechanical functions of propulsion of the molten material
Data Source
AI summary
A method of laser processing of a metallic material is described by means of a focused laser beam having a predetermined transverse power distribution on at least one working plane of the material, comprising the steps of:providing a laser beam emitting source;leading the laser beam along a beam transport optical path to a working head arranged in proximity to the material;collimating the laser beam along an optical axis of propagation incident on the material;focusing the collimated laser beam in an area of a working plane of the material; andconducting the focused laser beam along a working path on the metallic material comprising a succession of working areas,wherein the laser beam is shaped:by reflecting the collimated beam by means of a deformable controlled surface reflecting element having a plurality of independently movable reflection areas, andby controlling the arrangement of the reflection areas to establish a predetermined transverse power distribution of the beam on at least one working plane of the metallic material as a function of the area of the current working plane and/or of the current direction of the working path on the metallic material.