Fiber Bundle Beam Switching for Real-Time Laser Spot Control
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Solution Overview
Problem
High-power laser systems require frequent adjustments to achieve varying beam spot sizes and qualities for different materials and processes, which is time-consuming and costly, and existing methods involve swapping or realigning optical components, risking damage.
Innovation Solution
A laser system with a fiber bundle of optical fibers of varying core diameters and cladding regions, where the laser beam is directed into specific fibers or regions to control beam shape and parameter product, allowing for adjustable beam profiles without altering the output optical system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical components are swapped or realigned to adjust beam spot size and quality, then beam parameters can be changed for different materials and processes, but the process becomes time-consuming and costly, and there is risk of damage to fragile optical components
Solution Approach 1:
The patent implements dynamic beam parameter control by using a deformable mirror that can change its surface shape in real-time through piezoelectric actuators. This allows the laser beam parameters (spot size, quality, shape) to be adjusted dynamically without physical component swaps, resolving the contradiction between adaptability and time loss
Solution Approach 2:
The patent changes the physical parameter of the deformable mirror surface (shape/curvature) to control beam parameters. By varying the mirror surface geometry through controlled deformation, the system achieves different beam spot sizes and qualities without mechanical reconfiguration, eliminating adjustment time while maintaining full adaptability
2Adaptability or versatility
If optical components are swapped or realigned to adjust beam spot size and quality, then beam parameters can be changed for different materials and processes, but the system complexity and cost increase due to multiple components
Solution Approach 1:
The deformable mirror serves multiple functions simultaneously: it focuses the beam, adjusts spot size, controls beam quality, and shapes the beam profile. This single multi-functional component replaces what would traditionally require multiple separate optical elements, reducing system complexity while maintaining full beam parameter variability
Solution Approach 2:
The patent combines multiple optical functions (focusing, beam shaping, quality control) into a single deformable mirror component. By merging these functions into one adaptive element, the system achieves complex beam parameter control without the complexity of multiple discrete optical components
3Adaptability or versatility
If optical components are swapped or realigned to adjust beam spot size and quality, then different beam characteristics can be achieved, but the risk of damage to fragile optical components increases
Solution Approach 1:
The deformable mirror is a solid-state piezoelectric device with no fragile optical surfaces that require alignment or physical handling. It adjusts beam characteristics through electrical control of its surface shape, eliminating the need for manual component manipulation and thereby preventing damage while maintaining full beam shape control capability
Solution Approach 2:
The patent replaces mechanical optical component adjustment systems with an electrically-controlled piezoelectric deformable mirror. This substitution eliminates mechanical handling, alignment, and physical contact with fragile optics, thereby improving reliability and preventing damage while achieving the same beam control objectives
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
Enables efficient and flexible processing of various materials by varying the beam shape and parameter product in real-time, reducing the need for component swaps and minimizing risk of damage, while allowing multiple outputs with different characteristics from a single system.
Implementation Method 1
the laser light from which is coupled into an optical fiber
Implementation Method 2
an optical system that focuses the laser light from the fiber onto the workpiece to be processed
Data Source
AI summary
In various embodiments, the beam parameter product and/or beam shape of a laser beam is adjusted by coupling the laser beam into an optical fiber of a fiber bundle and directing the laser beam onto one or more in-coupling locations on the input end of the optical fiber. The beam emitted at the output end of the optical fiber may be utilized to process a workpiece.