Diode Laser Illuminator Interchangeable Modules Beam Expansion
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Solution Overview
Problem
Current diode-laser line projection systems require multiple diode-laser bars to achieve the necessary power for uniform spot formation in laser cladding, leading to inefficiencies and the need for multiple projectors for different spot shapes and powers, which is inconvenient and costly.
Innovation Solution
The optical apparatus uses a plurality of diode-laser bar stacks with beam-expanders and a spherical focusing lens to project radiation into a spot of predetermined dimensions, allowing for variable power and spot shapes with a single projector, by expanding beams only in the slow-axis direction to achieve uniform intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple diode-laser bars are used to achieve necessary power for uniform spot formation, then power is improved, but device complexity increases
Solution Approach 1:
The laser source is segmented into multiple diode-laser bars arranged in stacks, with each bar contributing to the total power while maintaining individual beam control through separate collimating lenses, resolving the contradiction between achieving high power and managing device complexity
Solution Approach 2:
Multiple diode-laser bars are merged into stacked configurations where their beams are combined through optical elements (collimating lenses and beam expanders) to form a unified spot pattern, achieving the necessary power level while consolidating the complexity into a modular stacked architecture
2Adaptability or versatility
If different projectors are used for different spot shapes and powers, then spot shape adaptability is improved, but device complexity increases
Solution Approach 1:
A single projector system is designed with interchangeable module capabilities, where different diode-laser bar stack configurations and beam expander settings enable the same hardware to produce multiple spot shapes and power levels, eliminating the need for multiple dedicated projectors
Solution Approach 2:
The system incorporates dynamic reconfigurability through interchangeable modules that allow users to switch between different spot shapes and power configurations on demand, providing adaptability without requiring multiple fixed projectors for each configuration
3Area of moving object
If beam expansion is applied in both fast-axis and slow-axis directions, then spot dimensions are improved, but intensity uniformity deteriorates
Solution Approach 1:
Beam expansion is applied selectively with different expansion ratios in the fast-axis and slow-axis directions, allowing independent optimization of spot dimensions in each direction while maintaining intensity uniformity through localized control of the expansion parameters
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 enables efficient projection of radiation into spots with uniform intensity, allowing for different spot shapes and powers with a single apparatus, reducing the need for multiple projectors and improving operational efficiency and cost-effectiveness.
Implementation Method 1
Each of the beam-expanders is arranged to expand the beam from the corresponding diode-laser bar stack in the slow-axis direction only
Implementation Method 2
An optical arrangement including a spherical focusing lens is arranged to collect the slow-axis expanded beams and project the slow-axis expanded beams into the working plane to form the length of the radiation spot
Implementation Method 3
Each stack is arranged to provide a beam of laser radiation. The diode-laser bars have a length, a slow-axis aligned with the length, a fast-axis perpendicular to the slow-axis, and a propagation-axis perpendicular to the fast-axis and the slow-axis
Data Source
AI summary
Projection apparatus for projecting a radiation spot on a working plane includes a plurality of stacks of diode-laser bars. Each stack provides a beam of laser radiation. The diode-laser bars in each stack are arranged one above another in the fast-axis direction of the diode-laser bars. A corresponding plurality of beam-expanders expands the beam from the corresponding diode-laser bar stack in the slow-axis direction of the diode laser bars only. A focusing lens collects the slow-axis expanded beams and projects the slow-axis expanded beams into the working plane to form the radiation spot.