Dynamic Laser Drilling Head for Round Holes During Continuous Motion
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Solution Overview
Problem
Existing laser drilling systems face challenges in producing high numbers of uniform round holes efficiently while maintaining cost-effectiveness and meeting market requirements, particularly in applications like filter manufacturing where hole ovalization and reduced drilling frequency lead to increased production time and costs.
Innovation Solution
The proposed laser drilling system incorporates a dynamic compensator with galvo mirrors in the laser head, allowing for controllable beam guidance to maintain a fixed spatial and temporal relationship between the beam spot and the workpiece during drilling, thereby preventing hole elongation and enabling high-throughput production of uniform round holes. Additionally, the system includes a fiber delivery system for outputting differently shaped beams, allowing for the production of various hole geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser head is continuously displaced during laser pulse to increase drilling frequency, then productivity is improved, but the hole circularity deteriorates due to beam spot dragging
Solution Approach 1:
The patent applies dynamics by making the beam guiding optic movable relative to the laser head, allowing it to dynamically adjust its position to compensate for the laser head's displacement. This creates a dynamic compensation mechanism where the beam guiding optic moves in coordination with the laser head movement to maintain proper beam alignment and hole circularity while enabling continuous laser operation at high drilling frequencies
Solution Approach 2:
The beam guiding optic serves as an intermediary element between the laser head and the workpiece. It mediates the interaction by redirecting the laser beam and compensating for relative movements, allowing the system to maintain precise beam positioning on the workpiece even when the laser head is in continuous motion, thus preserving hole circularity while enabling high productivity
2Manufacturing precision
If the laser pulse width is increased to improve hole production quality, then manufacturing precision is improved, but the productivity deteriorates due to stage movement during pulse width
Solution Approach 1:
The system uses dynamic movement of the beam guiding optic to compensate for stage movement during extended laser pulse widths. This allows the beam spot to remain stationary on the workpiece despite stage displacement, enabling longer pulse durations for better hole quality without sacrificing drilling frequency or productivity
3Productivity
If the laser head velocity is increased to improve productivity, then drilling frequency is improved, but the hole circularity deteriorates due to beam spot dragging in direction of displacement
Solution Approach 1:
The beam guiding optic is designed to move dynamically at velocities matching the laser head displacement. This dynamic compensation allows the system to operate at high laser head velocities for improved productivity while the beam guiding optic simultaneously compensates for the dragging effect, maintaining hole circularity despite high-speed operation
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 solution achieves high throughput and cost-efficient production of uniform round holes, meeting market requirements while avoiding the issues of hole ovalization and reduced drilling frequency. The system's ability to produce a variety of hole geometries expands its applicability across different industrial needs.
Implementation Method 1
The laser source may include a variety of solid body lasers, such as fiber lasers operating in a quasi-continuous wave (QCW) or pulsed regime
Implementation Method 2
a single pulse produces a hole
Implementation Method 3
The dynamic compensator is configured to controllably guide a laser beam
Implementation Method 4
the system includes a fiber delivery system for outputting differently shaped beams
Data Source
AI summary
A laser drilling system is configured with a combination of system components including a fiber laser source, laser processing head, dynamic compensator, configured with one or multiple galvanometers, and stage supporting the workpiece to be laser drilled. The system components are all functionally coupled to one another to provide a plurality of trepanned holes in the workpiece each with the desired geometry. The laser head and stage are continuously displaceable relative to one another while the dynamic compensator pivots so as to keep the laser spot and the predetermined drilling location stationary relative to one another over a predetermined period of time sufficient for drill the hole. The laser source is selected from solid-state lasers configured with a single core or multi-core delivery fiber. The multicore delivery fiber is associated with adjustable mode beam (AMB) lasers to provide annular, polygonal or irregular holes.