Laser Beam Shaping for Uniform Heat Treatment Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laser heat treatment systems face challenges in achieving uniform heat treatment across the surface and depth of a workpiece due to complex optical field control, high laser beam loss, and sensitivity to different wavelengths.
Innovation Solution
A system comprising a laser source, collimator mirror, spatial light modulator with a binary grating and mask, X-direction mirror, focusing assembly, and Y-direction mirror, which shapes and adjusts the laser beam's energy density through diffraction and masking, enabling uniform heating and dynamic scanning for consistent heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple laser light sources are used with multi-plane phase adjustment to achieve uniform heating, then the uniformity of heat treatment is improved, but the device complexity and optical system loss increase significantly
Solution Approach 1:
The patent segments the laser beam into multiple sub-beams using a diffractive optical element (binary grating), then uses a spatial light modulator to independently control the phase and amplitude of each sub-beam. This segmentation approach replaces the complex multi-plane phase adjustment system with a more manageable single-plane spatial modulation system, reducing optical component complexity while maintaining beam uniformity control capability
Solution Approach 2:
The patent introduces a spatial light modulator as an intermediary device that directly modulates the amplitude and phase of the laser beam in the spatial domain. This intermediary replaces the need for complex multi-plane phase adjustment optics, simplifying the optical system while achieving the same uniformity control objective through direct spatial encoding
2Manufacturing precision
If multiple laser light sources are used with multi-plane phase adjustment to achieve uniform heating, then the uniformity of heat treatment is improved, but the energy loss of laser beam increases
Solution Approach 1:
The spatial light modulator acts as an efficient intermediary that directly modulates the laser beam amplitude and phase without requiring multiple optical planes and beam combining optics. This direct modulation approach minimizes optical interfaces and reflections, reducing energy loss while achieving uniform beam distribution for consistent heat treatment
3Ease of operation
If conventional heat treatment methods are used, then the process is simple, but the uniformity of heat treatment across surface and depth is poor
Solution Approach 1:
The patent replaces conventional mechanical heat treatment methods with a laser-based system that uses spatial light modulation to control energy distribution. The spatial light modulator enables precise control of laser beam intensity and phase profiles, achieving uniform heating across both surface and depth without the mechanical complexity of traditional methods, thus improving uniformity while maintaining operational simplicity through digital control
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 system achieves uniform heat treatment across the workpiece surface and depth, improving thermal efficiency and consistency of the hardened layer, while reducing material damage and energy loss.
Implementation Method 1
The incident laser beam is shaped by a binary grating to remove higher-order beams, change a diffraction angle and a diffraction efficiency of the laser beam
Implementation Method 2
The energy density distribution of the laser beam is adjusted by a grating density of a mask
Implementation Method 3
Laser can be used for heat treatment, and the surface of metal is treated by a laser beam with a high power density to achieve phase change hardening of the metal
Data Source
AI summary
A system for shaping a beam and adjusting a beam energy density includes a laser source, a collimator mirror, a spatial light modulator, an X-direction mirror, a focusing assembly, and a Y-direction mirror. The spatial light modulator includes a binary grating and a mask which are disposed in sequence. A laser beam emitted by the laser source sequentially passes through the collimator mirror, the spatial light modulator, the X-direction mirror, the focusing assembly, and the Y-direction mirror, the laser beam is shaped by changing a diffraction period of the binary grating, an energy density distribution of the laser beam is changed by adjusting a grating density of the mask, and the X-direction mirror and the Y-direction mirror are used for a dynamic scanning movement of the laser beam.