Galvano-Scanner Drive Pattern Creation via Manual Laser Teaching
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Solution Overview
Problem
Creating a drive pattern for a galvano-scanner system is time-consuming and requires extensive expertise due to the need for entering and setting a large amount of information, including coordinates, scan speed, and correction data, which is prone to errors from optics system distortion and other causes.
Innovation Solution
A method involving a teaching operation where a visible laser beam is manually aligned at positioning points on a master work, with position information recorded and used to generate a drive pattern for the main laser beam, eliminating the need for pre-entered correction data and allowing for error correction, and optionally adjusting scan speed and adding auxiliary movements to minimize overshooting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional methods are used to create drive pattern input commands with pre-entered correction data, then manufacturing precision can be maintained, but the ease of operation deteriorates due to the need to enter and set a large amount of information
Solution Approach 1:
The system performs self-calibration by automatically measuring the actual positions of positioning points using the visible laser beam and galvano-scanner, and autonomously generating correction data without requiring manual entry of coordinates and correction parameters. This eliminates the need for operators to input large amounts of information while maintaining high precision.
Solution Approach 2:
The manual mechanical process of entering coordinates and correction data is replaced by an automated optical measurement system using a visible laser beam to detect positioning points and a computer algorithm to generate the drive pattern command, significantly reducing operation time and complexity.
2Ease of manufacture
If manual entry of correction data is performed, then manufacturing precision can be maintained, but device complexity increases due to the need for multiple data inputs
Solution Approach 1:
The complex task of manually entering and calculating correction data is extracted from the drive pattern creation process. The system automatically extracts position information by having the operator simply move the visible laser beam to positioning points, while the computer autonomously calculates all necessary correction data and generates the final command.
3Productivity
If pre-correction data is entered in advance, then manufacturing precision can be maintained, but productivity decreases due to time-consuming setup
Solution Approach 1:
The system performs preliminary calibration by automatically measuring the actual positions of positioning points and generating correction data before actual laser processing begins. This preliminary automated measurement ensures high precision is built into the system beforehand, eliminating the need for time-consuming manual data entry while maintaining accuracy.
4Measurement precision
If extensive correction data is entered, then manufacturing precision can be maintained, but ease of operation deteriorates due to expertise requirements
Solution Approach 1:
The system performs self-calibration by automatically measuring positioning points and generating correction data without requiring the operator to have expertise in entering and calculating correction parameters. The computer autonomously completes all complex calculations and data processing, making the system easy to operate while maintaining high precision.
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 method simplifies the creation of a drive pattern by removing errors from optics system distortion and other causes, reducing preparation time and expertise, while allowing for high accuracy and minimizing overshooting, thus enabling efficient and accurate scanning without the need for complex pre-correction data.
Implementation Method 1
a visible laser beam is scanned via each positioning point on a surface of a work
Implementation Method 2
position information of the aligned galvano-scanner is obtained from a position sensor attached to the galvano-scanner
Data Source
AI summary
A visible laser beam scanned by a galvano-scanner system is aligned at each of positioning points on the top surface of a master work by manual operation to record sensor position signals of position sensors on galvano-scanners. The sensor position signals on each positioning point are recorded to create a drive pattern in accordance with recorded sensor position signals. The drive pattern no longer has optics system error sources including focus error and attachment error as well as errors caused by scale, offset and the like, also eliminating the need for entering a distance as far as the top surface of the work. Therefore, the drive pattern with error components removed can be created with ease.