Exchangeable Optical Module for Fast Laser Optics Replacement
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Solution Overview
Problem
Existing laser machine tools face challenges in quickly and easily exchanging optical components, which are prone to wear and contamination, affecting the efficiency and accuracy of laser beam intensity adjustment during machining processes.
Innovation Solution
An optical module with a housing that allows for the releasable attachment of multiple optical components, including collimation and focusing optics, deflecting mirrors, and a powder nozzle, enabling quick exchange and precise positioning, as well as automatic adjustment of the laser beam diameter and intensity during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If optical components are made exchangeable to extend lifespan and reduce maintenance time, then maintenance time is reduced and component lifespan is extended, but device complexity increases due to the need for exchange mechanisms and positioning systems
Solution Approach 1:
The optical module is divided into separable components (optical elements, housing, mounting mechanisms) that can be independently exchanged. This segmentation allows quick replacement of worn optical components without replacing the entire system, reducing maintenance time while managing complexity through modular design
Solution Approach 2:
The housing and mounting mechanisms are designed to accommodate multiple types of optical components through standardized interfaces. This universality allows a single exchange mechanism to handle different optical elements, reducing the need for multiple specialized systems and thereby managing device complexity
2Productivity
If multiple optical components are integrated in one housing to enable automatic exchange, then productivity is improved through automated adjustment, but device complexity increases due to integration requirements
Solution Approach 1:
Multiple optical components (collimation optics, focusing optics, deflecting mirrors) are integrated into a single housing assembly that can be automatically exchanged as one unit. This merging enables automated productivity improvements while containing complexity within a standardized module interface
Solution Approach 2:
The optical components are pre-positioned and pre-aligned within the housing during manufacturing. This preliminary action ensures that when the module is automatically exchanged, the optical components are already in their correct positions and orientations, enabling immediate productivity without requiring complex real-time alignment mechanisms
3Manufacturing precision
If optical components are made easily exchangeable to maintain beam quality, then manufacturing precision is maintained through consistent beam quality, but ease of manufacture decreases due to precise positioning requirements
Solution Approach 1:
Optical components are pre-aligned and pre-positioned within the housing during the manufacturing process. This preliminary action ensures that when modules are exchanged, the optical path is already optimized, maintaining beam quality consistency without requiring complex real-time adjustment mechanisms during operation
Solution Approach 2:
The housing and mounting mechanisms are designed with self-aligning features (such as tapered mounts, precision locators, or compliant elements) that automatically position optical components correctly upon insertion. This self-service capability maintains manufacturing precision while simplifying the exchange process and reducing the need for complex external alignment systems
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 reduces maintenance time, extends the lifespan of optical components, and ensures consistent beam quality by allowing for automatic exchange and adjustment of optical components, enhancing the efficiency and versatility of laser machining processes.
Implementation Method 1
The material powder is heated by a focused laser beam in a predetermined area corresponding to a selected cross-sectional area of the model of the molded body so that the material powder is remelted in the irradiated areas to form connected solidified regions
Implementation Method 2
heating by a focused laser beam
Implementation Method 3
The beam diameter of the laser beam is usually determined by the focal length of a focusing optics and by the beam diameter of the collimated laser beam in front of the focusing optics. The beam diameter of the collimated laser beam can be determined in particular by the focal length of a collimation optics
Data Source
AI summary
An optical module for a machine for machining workpieces and/or for producing molded bodies by location-selective solidification of material powder to form connected regions by a focused laser beam includes a housing for releasably attaching the optical module to the machine and a plurality of optical components are arranged in or on the housing to collimate and focus the laser beam.