Laser Beam Shaping and Rotation for Real-Time Process Alignment
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Solution Overview
Problem
Current laser machining systems face challenges in dynamically adjusting beam shape and orientation during processing, particularly for irregular or spatially oriented components, due to limitations in existing beam shaping technologies such as fixed diffractive optical elements and scanner systems, which result in reduced processing quality and increased costs.
Innovation Solution
The method involves dynamically adapting the beam shape and orientation using a Spatial Light Modulator (SLM) and beam profile rotating optics, such as Dove prisms and cylindrical lens telescopes, to align the laser beam with the processing speed and component geometry, enabling real-time optimization of the beam's intensity distribution and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed diffractive optical elements (DOEs) are used to shape the beam, then the intensity distribution can be adjusted within certain limits, but the changeover time is too long compared to the process time
Solution Approach 1:
The patent replaces fixed DOEs with a spatial light modulator (SLM) that can dynamically change the beam shape in real-time. The SLM is controlled by a control unit that receives geometry data and feed rate information, allowing the beam intensity distribution to be adjusted on-the-fly without physical exchange of optical elements, thus eliminating changeover time while maintaining manufacturing precision.
Solution Approach 2:
The invention changes the operational parameters of the beam shaping system by using an SLM that can modulate the spatial distribution of the laser beam according to varying process parameters. The control unit calculates appropriate beam shapes based on component geometry and feed rate, then programs the SLM accordingly, enabling continuous parameter adaptation during processing.
2Adaptability or versatility
If multiple DOEs are used for different processes, then various beam shapes can be achieved, but the cost increases significantly
Solution Approach 1:
The patent employs a single spatial light modulator (SLM) that can perform multiple beam shaping functions for different processes and geometries. The SLM is programmable and can be reconfigured via software to generate various beam intensity distributions, replacing the need for multiple specialized DOEs and significantly reducing system cost while maintaining versatility.
Solution Approach 2:
Instead of using multiple physical optical elements (DOEs) for different beam shapes, the invention uses a single SLM that creates virtual copies of different beam shaping functions through software programming. The control unit stores geometry data and calculates appropriate beam shapes, which are then implemented by programming the SLM, eliminating the need for expensive physical copies of optical elements.
3Measurement precision
If a scanner system is used with fixed beam shapers, then beam positioning is accurate, but image distortion occurs in the processing plane
Solution Approach 1:
The patent implements a feedback mechanism where the control unit receives information about the actual beam position and component geometry, then adjusts the SLM programming accordingly. This closed-loop control allows the system to compensate for scanner-induced distortions by dynamically adjusting the beam shape to match the actual processing conditions, maintaining both positioning accuracy and image fidelity.
4Manufacturing precision
If the beam shape is adapted to irregular contours, then processing quality improves, but the system complexity increases
Solution Approach 1:
The patent introduces a control unit as an intermediary between the scanner system and the SLM. This control unit receives component geometry data and feed rate information, calculates the appropriate beam shape adjustments, and programs the SLM accordingly. By centralizing the control logic in software, the system achieves complex beam shaping for irregular contours without proportionally increasing hardware complexity.
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 approach allows for high-precision, dynamic beam shaping and orientation adjustments, improving processing quality and efficiency by adapting to changing processing conditions without pausing the process, thus enhancing productivity and flexibility in laser processing systems.
Implementation Method 1
The beam shape is adapted to the feed vector of the processing speed by means of a spatial light modulator (SLM) unit in the beam shaping module
Implementation Method 2
Beam shaping by means of phase modulation can advantageously be achieved using an LCoS-SLM unit... Beam shaping using amplitude modulation can be achieved using a DMD unit
Implementation Method 3
Beam profile rotation can be generated by a so-called Dove prism
Implementation Method 4
Alternatively, the rotation of a cylindrical lens telescope can be used for beam profile rotation
Implementation Method 5
a laser beam is focused onto the surface of a component in a laser processing system by means of deflecting mirrors and lens systems
Data Source
Figure 1~2
Figure 3a~6
AI summary
The invention relates to a method for beam shape and beam orientation adjustment in a laser processing process and a laser processing system, which has at least one process control unit and an application program, a laser beam source, a beam shaping module and beam profile rotating optics, with which a laser beam is adjusted in real time to a Feed rate vector and can be adapted to the topography of the workpiece to be machined. For example, rotating Dove prisms and/or cylindrical lens telescopes are used for rotating the beam profile. The beam shape can be adjusted using so-called Liquid Crystal on Silicon Spatial Light Modulators (LCoS-SLM) or Digital Micro-Mirror Devices. Laser processing can thus be significantly improved in terms of quality and productivity. With this concept, modular laser processing systems can be implemented. Existing systems can be retrofitted.