Dual-Laser Beam Diameter Control for Stable Copper Processing
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Solution Overview
Problem
Existing laser processing machines using superimposed blue and infrared lasers often fail to achieve high-quality processing of various workpieces due to inconsistencies in beam diameter ratios, leading to issues like unstable keyholes, spatters, and blowholes.
Innovation Solution
A laser processing machine and method that adjust the beam diameters of blue and infrared laser beams based on the material of the workpiece, using a beam diameter adjustment mechanism and controller to optimize the ratio between the two beams, ensuring stable and high-quality processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If blue laser and infrared laser are superimposed on each other to process copper workpieces, then processing capability on copper is improved, but processing quality becomes unstable due to inconsistent beam diameter ratios
Solution Approach 1:
The patent adjusts the beam diameter ratio parameter between blue and infrared lasers by changing optical system parameters (lens focal lengths, beam expansion ratios) to optimize processing quality. The controller dynamically adjusts the beam diameter ratio based on workpiece material and thickness, transforming a fixed parameter system into an adjustable one that maintains stable keyhole formation and molten pool characteristics.
2Ease of operation
If beam diameter ratio is not adjusted according to workpiece material, then device operation is simple, but processing quality deteriorates with spatters and blowholes
Solution Approach 1:
The controller receives information about workpiece material and thickness, then automatically adjusts the beam diameter ratio of the lasers accordingly. This feedback mechanism eliminates the need for manual intervention while preventing harmful effects like spatters and blowholes by optimizing the beam parameters for each specific workpiece type.
Solution Approach 2:
The system transitions from a static beam diameter ratio to a dynamic one that changes based on workpiece characteristics. The beam diameter adjustment mechanism allows the optical system to adapt its parameters in real-time, making the processing system flexible and responsive to different material conditions.
3Device complexity
If fixed beam diameter ratio is used for all materials, then device complexity is reduced, but processing stability deteriorates leading to unstable keyholes
Solution Approach 1:
The patent introduces adjustable parameters in the optical system (beam expansion ratios, lens selection) that allow the beam diameter ratio to be optimized for different materials. This parameter adjustment capability stabilizes keyhole formation and molten pool characteristics without requiring fundamentally complex optical components.
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 system enables high-quality processing of diverse materials by stabilizing the molten pool and metal flow, reducing spatters and blowholes, and achieving both processing accuracy and speed.
Implementation Method 1
a first laser oscillator configured to emit a first laser beam having a first wavelength
Implementation Method 2
a second laser oscillator configured to emit a second laser beam having a second wavelength different from the first wavelength
Implementation Method 3
The blue laser provides an optical absorptance higher than that of the infrared laser, and hence the blue laser is expected to improve processing performance at the time of processing a copper sheet
Data Source
AI summary
A processing head of a laser processing machine irradiates a workpiece with first and second laser beams radiated from ends of first and second transmission fibers. A beam diameter adjustment mechanism operates an optical system for at least one of the first and second laser beams inside the processing head. A controller controls the beam diameter adjustment mechanism to adjust a ratio between a first beam diameter and a second beam diameter in accordance with at least a material of the workpiece. The first beam diameter is a beam diameter of the first laser beam at a position at which the first laser beam irradiates the workpiece, and the second beam diameter is a beam diameter of the second laser beam at a position at which the second laser beam irradiates the workpiece.