Discrete Glass Channel Grooving for Precise Length and Depth
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Solution Overview
Problem
Existing glass channel grooving technologies require continuous operation, leading to reduced spindle and engine life, high costs due to multiple discs, and inability to meet consumer demands for precise channel dimensions.
Innovation Solution
A discrete channel grooving system utilizing an encoder, pneumatic valve, and channel engine to enable grooving at desired dimensions, reducing the number of discs and optimizing channel opening with PLC software control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grooving methods (single-point diamond turning, laser, electro-discharge) are used, then grooves can be formed in optical elements, but the surfaces exhibit irregularities and deviations from nominal surface profiles due to tool interaction with the workpiece
Solution Approach 1:
The patent replaces conventional mechanical grooving methods (single-point diamond turning) with a laser-based method. The laser beam interacts with the workpiece through optical absorption and thermal conduction, melting and vaporizing material without mechanical contact, thereby eliminating tool-induced surface irregularities and achieving higher surface profile accuracy.
Solution Approach 2:
The patent utilizes phase transitions of material (solid to liquid to gas) through laser heating. The laser energy causes localized melting and subsequent vaporization of the workpiece material, enabling precise groove formation without mechanical tool contact and the associated surface defects.
2Adaptability or versatility
If conventional grooving methods are used, then grooves can be formed, but the process is time-consuming and lacks adaptability for different groove geometries
Solution Approach 1:
The patent employs dynamic control of the laser beam parameters (power, focal position, scanning speed) and multi-axis motion to adaptively create various groove geometries. This dynamic adjustment enables rapid switching between different groove profiles without changing physical tools, enhancing both versatility and productivity.
Solution Approach 2:
The laser-based grooving system serves multiple functions: it can create different groove geometries, adjust groove depth and width, and modify surface properties all through software-controlled laser parameters, replacing multiple specialized tools with a single universal system.
3Loss of substance
If conventional grooving methods are used, then material can be removed to form grooves, but there is significant material waste and poor adaptability to complex three-dimensional surfaces
Solution Approach 1:
The patent applies localized laser heating precisely where groove formation is needed, with controlled heat zones that minimize thermal damage to surrounding areas. The laser beam can be focused to specific depths and positions, removing only the necessary material while preserving the integrity of the surrounding workpiece, thus reducing material waste.
Solution Approach 2:
The patent extends grooving capability from traditional two-dimensional surfaces to three-dimensional complex surfaces by incorporating multi-axis motion control and adjustable focal positions. This enables precise material removal on curved and irregular surfaces while maintaining minimal material waste through precise laser positioning.
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
Extends spindle and engine life, reduces costs, and meets consumer demands by allowing precise channel grooving at desired lengths and depths on glass surfaces.
Implementation Method 1
A laser is used to heat and melt material in a workpiece
Implementation Method 2
The laser is used to heat and melt material in a workpiece and then vaporize the melted material by ablation
Data Source
Figure 1
AI summary
The invention particularly relates to the discrete channel grooving system (10), which reduces costs by using fewer discs and allows channel engraving at the desired length and depth in the desired area of the glass. The discrete grooving system (10) which has been developed to be used for grooving channels in the glass sector, in its simplest form, comprises DOP screen (11), which enables channel opening on the glass via the software it contains, the encoder (12), which determines the speed of the machine and calculates the path taken by the glass per unit time to measure the channel, the switch (13) for detecting the incoming glass by the channel engine (15), pneumatic valve (14) for moving the channel engine (15) up and down, and an channel engine (15) for grooving discrete channels by moving up and down on the glass.