Laser Drilling Machine with Voice Coil Actuators
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Solution Overview
Problem
Existing high-speed laser drilling machines are limited by the slow positioning between holes due to the high moving mass and inertia, resulting in significant cycle time spent on moving the worktable and laser head, and frequent shutter opening/closing, which increases the overall drilling duration.
Innovation Solution
A high-speed laser drilling machine with a five-degree-of-freedom motion system utilizing high-speed linear motor drives and a parallel kinematics structure, allowing for rapid and precise alignment of the laser head with the workpiece between laser pulses, eliminating the need for shutter closure during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional ball screw feed drives are used with high moving mass, then positioning accuracy can be maintained, but positioning speed and acceleration are limited
Solution Approach 1:
The patent replaces traditional ball screw mechanical feed drives with direct-drive voice coil actuators that utilize electromagnetic fields for positioning. This substitution eliminates mechanical transmission components, significantly reducing moving mass and inertia while enabling faster acceleration and positioning speeds essential for high-speed laser drilling.
Solution Approach 2:
The patent changes the fundamental operating parameters by using voice coil actuators capable of achieving accelerations up to 100g compared to traditional ball screw systems. This parameter change enables the system to position the laser head and worktable rapidly between holes without the speed limitations imposed by high moving mass.
2Productivity
If the laser shutter is opened and closed for each hole position, then precise positioning can be achieved, but cycle time increases significantly
Solution Approach 1:
The patent maintains continuous laser operation by eliminating repeated shutter opening and closing cycles. The high-speed positioning system enables the laser to remain active while the worktable and laser head are rapidly repositioned between holes, converting what was previously a discontinuous process into a continuous operation that dramatically reduces cycle time.
Solution Approach 2:
The patent performs preliminary positioning of the laser head and worktable using high-speed actuators before each laser pulse, enabling the laser to fire continuously without waiting for mechanical repositioning. This preliminary action allows the useful drilling action to proceed without interruption by the positioning cycle.
3Measurement precision
If the laser head and worktable are moved between holes, then precise hole positioning is achieved, but positioning time dominates the drilling cycle
Solution Approach 1:
The patent replaces traditional mechanical positioning systems with direct-drive voice coil actuators that provide both high precision and high speed. These actuators can rapidly adjust the position of the laser head and worktable with micrometer-level precision while achieving positioning times measured in milliseconds rather than seconds.
Solution Approach 2:
The patent transitions from static, slow mechanical positioning to dynamic high-speed positioning using voice coil actuators. The system can rapidly change position and acceleration states to match the laser pulse frequency, enabling the positioning time to be a small fraction of the total cycle time rather than the dominant portion.
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 configuration enables a substantial increase in drilling rate, up to 20 times faster than traditional machines, by synchronizing the relative movement of the laser head and workpiece with the laser pulse frequency, minimizing non-drilling tasks and allowing for efficient drilling of irregularly distributed holes with variable angles.
Implementation Method 1
The laser head positioning system includes a first voice coil actuator for moving the laser head along the x-axis and a second voice coil actuator for moving the laser head along the y-axis; The worktable positioning system includes a third voice coil actuator for moving the worktable along the x-axis and a fourth voice coil actuator for moving the worktable along the y-axis
Implementation Method 2
A controller synchronizes a relative movement between the laser head and the workpiece with a frequency of the pulsed laser. A method according to any of claims 1-12, wherein the relative movement between the laser head and the workpiece is synchronized with a frequency of the pulsed laser
Data Source
Figure 1
Figure 2
AI summary
A method of laser drilling a series of holes at spaced-apart hole locations in a workpiece (18; 118; 218) including continually delivering laser pulses to the workpiece (18; 118; 218), and positioning the workpiece (18; 118; 218) relative to the laser head (36; 136; 236) from one hole location to a next within a time between two consecutive pulses.