Five-Dimensional Laser Scanning for Precise Complex Part Processing
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Solution Overview
Problem
Traditional laser processing equipment, relying on multi-axis CNC machine tools, suffers from limited processing accuracy, slow speed, and wear errors due to continuous start and stop, which hinder high-speed and high-efficiency processing of complex parts.
Innovation Solution
A five-dimensional laser scanning processing device comprising a laser emitting device, beam expansion module, plane scanning module, and focusing module, with integrated turning and deflection modules, allows for multi-dimensional beam manipulation in XYZ planes and angles α and β, enabling precise and efficient processing of complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-axis CNC machine tools are used for laser processing, then complex parts can be processed, but processing accuracy is limited due to multi-axis motion errors
Solution Approach 1:
The patent segments the complex multi-axis motion system into separate functional modules: a two-axis scanner for XY plane scanning and a focusing module for Z-axis control. This segmentation eliminates the need for complex multi-axis CNC machine tools while maintaining the ability to process complex parts, thereby improving processing accuracy by removing multi-axis motion errors.
Solution Approach 2:
The patent transitions from controlling complex spatial trajectories through multi-axis mechanical motion to controlling light beam propagation in five-dimensional space (XYZ coordinates plus two inclination angles α and β). This dimensional change allows precise control of the focused spot's position and orientation without relying on complex mechanical multi-axis systems.
2Productivity
If multi-axis CNC machine tools are used for laser processing, then complex parts can be processed, but processing speed is slow due to continuous start and stop
Solution Approach 1:
The patent enables continuous laser beam scanning by separating the scanning function (XY plane) from the focusing function (Z axis). The two-axis scanner can continuously scan the laser beam across the workpiece while the focusing module continuously adjusts the focal position, eliminating the need for repeated start and stop operations required by multi-axis CNC systems, thereby improving processing speed and productivity.
Solution Approach 2:
The patent replaces the mechanical multi-axis CNC system with an optical-electromechanical system consisting of a two-axis scanner and focusing module. This substitution eliminates mechanical constraints and continuous start-stop operations, allowing for high-speed continuous processing while maintaining the ability to handle complex geometries.
3Manufacturing precision
If beam radius is reduced for precise focusing, then spot size decreases, but aberrations increase
Solution Approach 1:
The patent segments the beam control function into two independent modules: beam expansion for controlling spot size and focusing for controlling focal position. The beam expansion module expands the laser beam to reduce aberrations, while the focusing module then focuses the expanded beam to achieve a small spot size. This segmentation allows optimization of each module's function independently, reducing overall system aberrations while maintaining precise focusing capability.
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 device achieves efficient and fast processing of complex microstructures by controlling laser beam movements in five dimensions, eliminating the need for multi-axis CNC machine tools and enhancing processing accuracy and speed.
Implementation Method 1
the beam expansion module 4 is used to expand the beam radius of the laser beam 1. After beam expansion, it is more conducive to laser focusing, converging the light spot into a smaller size, and it is also easier to reduce aberrations
Implementation Method 2
The plane scanning module 6 is composed of two reflective mirrors at a certain angle. Through the continuous deflection of the two reflective mirrors, the scanning of the laser beam in the XY plane is achieved
Implementation Method 3
the laser beam finally enters the focusing module 5 and converges into an ideal spot (with a spot diameter about 20 μm)
Data Source
AI summary
The present invention discloses a multi-dimensional laser scanning processing device and method, which includes a horizontally arranged laser beam, a turning optical path module arranged at one end of the laser beam along a horizontal direction. The turning optical path module is used to deflect the laser beam by 90°, which is then arranged to enter a deflection module. The deflection module is used to deflect the laser beam by 90° again so that it enters the beam expansion module along the horizontal direction. The beam expansion module 4 is arranged to expand a beam radius of the laser beam to a certain multiple, which then enters the plane scanning module, and finally enters the focusing module to converge into an ideal spot. The present invention can realize the changes of focused laser beam in the XYZ space and the two inclination angles α and β of the optical axis.