Laser End Effector Lattice Cooling for Higher Power Machining
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Solution Overview
Problem
Conventional laser machine tools face limitations in laser power due to weight and thermal cooling inertia, leading to reduced machining efficiency and increased encumbrance, as existing cooling methods dissipate power through diffraction and diffusion within the laser head's ducts.
Innovation Solution
An end effector with a heat exchanger featuring a lattice structure that increases the surface area for heat exchange, using a tortuous path for cooling liquid channels to enhance efficiency and reduce weight, integrated within the laser head's supporting body via additive manufacturing, allowing for higher laser power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional cooling methods are used in laser heads, then the structure is simpler and easier to manufacture, but the laser power is limited to 20 kW due to thermal cooling inertia and weight
Solution Approach 1:
The patent applies a lattice structure (porous material arrangement) within the heat exchanger that provides high surface area for heat dissipation while maintaining low weight. The lattice configuration allows efficient thermal management without the mass penalty of solid conventional cooling structures, enabling laser powers exceeding 20 kW.
Solution Approach 2:
The patent transitions from conventional linear or planar cooling channels to a three-dimensional lattice structure. This dimensional change maximizes the heat exchange surface area within the available volume, improving thermal management efficiency without proportionally increasing weight, thus enabling higher laser power operation.
2Power
If conventional cooling methods are used in laser heads, then the manufacturing process is simpler, but the heat exchange surface area is insufficient for high power lasers
Solution Approach 1:
The lattice structure creates a porous-like arrangement with numerous interconnected struts and surfaces that dramatically increase the heat exchange area. This configuration provides extensive surface area for thermal dissipation without occupying excessive volume, meeting the requirements for high-power laser cooling.
Solution Approach 2:
The lattice structure nests multiple cooling surfaces within a compact volume, creating a hierarchical arrangement of thermal pathways. This nested configuration maximizes heat exchange surface area density, allowing efficient cooling for high-power lasers within the constrained space of the laser head.
3Power
If more material is used to increase thermal cooling inertia, then the laser power handling capability improves, but the encumbrance and weight of the laser head increase
Solution Approach 1:
The lattice structure provides a porous material arrangement that delivers high thermal mass and cooling capability without the weight penalty of solid structures. The optimized lattice configuration achieves sufficient thermal inertia for high-power operation while maintaining lightweight characteristics that reduce encumbrance.
Solution Approach 2:
The patent employs a composite structure combining the lattice framework with selective material properties to achieve optimal thermal management. This composite approach provides the necessary thermal inertia for high-power lasers while minimizing weight, resolving the contradiction between power handling and weight.
4Speed
If the laser head weight is reduced to improve dynamics, then the encumbrance decreases and dynamics improve, but the thermal cooling inertia is reduced limiting laser power
Solution Approach 1:
The lattice structure resolves this contradiction by providing a lightweight yet thermally substantial configuration. The porous lattice arrangement maintains sufficient thermal inertia for high-power laser operation while minimizing mass to improve dynamics and reduce encumbrance, achieving both lightweight design and high power capability simultaneously.
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 solution enables increased heat exchange efficiency and a lighter structure, overcoming conventional laser power limitations, improving machining performance and reducing weight-related encumbrance, while maintaining thermal stability.
Implementation Method 1
a heat exchanger (400) for cooling systems (40) located in said supporting body (22) so as to occupy a volume (400a, 400b) that surrounds at least one portion of said tubular duct (26)
Implementation Method 2
said heat exchanger (400) has a lattice structure of thermally conductive elements (402) configured to allow passage of a cooling fluid into said heat exchanger (400)
Implementation Method 3
configured to direct a laser beam onto a working surface along an optical axis of propagation of the laser beam
Implementation Method 4
a duct (26, 28) configured to receive said laser beam and to guide said laser beam towards a working surface (16)
Data Source
AI summary
An end effector for a laser machine tool is configured to direct a laser beam onto a working surface along an optical axis of propagation of the laser beam. The end effector includes a supporting body having a duct with an axis parallel to at least one portion of the optical axis of propagation of the laser beam, and a further duct configured to be coupled to the supporting body and to provide an outlet for the laser beam.