Deformable-Mirror Laser Machining Head for Clean Beam Shaping
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Solution Overview
Problem
Laser machining heads are prone to contamination and mechanical abrasion due to the use of transmissive optical elements, which are sensitive to contamination and difficult to cool, leading to refractive index changes and beam shaping issues that can render the head unusable.
Innovation Solution
A laser machining device with a stationary deformable mirror system that adjusts focal position and magnification without displacing optical elements, using deformable mirrors with variable radius of curvature to shape the laser beam, allowing for compact design and reduced contamination risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If transmissive optical elements (lenses) are used to shape and guide the laser beam, then the laser beam can be effectively shaped for machining, but the optical elements are sensitive to contamination and difficult to cool, leading to refractive index changes and reduced performance
Solution Approach 1:
The patent replaces transmissive optical elements (lenses) with reflective optical elements (mirrors) to shape and guide the laser beam. This substitution eliminates the problems of contamination sensitivity and cooling difficulty associated with lenses, while maintaining the ability to effectively shape the beam for machining. The reflective mirrors are positioned in a contamination-free zone and can be actively cooled without affecting optical performance.
Solution Approach 2:
The patent introduces a reflective optical system as an intermediary between the laser source and the workpiece. This intermediary system uses mirrors instead of lenses to transmit and shape the laser beam, thereby mediating the problems of contamination and thermal management while preserving beam shaping capabilities.
2Adaptability or versatility
If lenses are displaced to adjust focal position or magnification, then the machining parameters can be changed, but mechanical abrasion occurs leading to contaminant generation and lens surface degradation
Solution Approach 1:
The patent replaces mechanical lens displacement mechanisms with a system that adjusts the position of reflective mirrors. This substitution eliminates mechanical abrasion and contaminant generation while maintaining the ability to adjust focal position and magnification. The mirrors are positioned in a contamination-free zone and can be adjusted without contacting the process zone.
Solution Approach 2:
Instead of moving the optical elements that shape the beam (lenses) through the contaminated environment, the patent inverts the approach by using reflective mirrors that are positioned in a contamination-free zone and adjusted from that clean environment, thereby avoiding mechanical abrasion and contamination.
3Length of stationary object
If the machining head is kept compact to fit within limited space, then the height constraint is satisfied, but the optical path length is reduced which may affect beam shaping quality
Solution Approach 1:
The patent uses reflective mirrors to fold the optical path, allowing a long optical path length to be achieved within a compact machining head height. By changing the dimensionality of the optical path (using multiple reflections at angles), the system maintains beam shaping quality while fitting within height constraints.
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 enables flexible beam shaping and focal position adjustment while avoiding contamination, resulting in a compact and durable machining head with rapid adjustment capabilities.
Implementation Method 1
the optical system has a first stationary, deformable mirror and a second stationary, deformable mirror, each of which is arranged and/or designed such that they each deflect the machining laser beam at an angle
Implementation Method 2
adjusting a radius of curvature of the first deformable mirror and/or a radius of curvature of the second deformable mirror, thereby a focal position of the machining laser beam and a magnification of the optical system are modified
Data Source
AI summary
A laser machining device and a laser machining method for machining a workpiece are specified. The laser machining device includes a laser machining head comprising a housing which has an interface for coupling a laser source for a machining laser beam and an outlet opening for the machining laser beam; and an optical system for shaping the machining laser beam and guiding the machining laser beam on an optical path with an overall length between the interface and the outlet opening. The optical system includes a first and a second stationary, deformable mirror, which are each arranged such that they each deflect the machining laser beam at an angle. The ratio of the overall length of the optical path between the outlet opening and the interface for coupling the laser source to the spatial extension of the housing parallel to the central axis of the outlet opening is in the range of 2 to 4.5.