Laser Tool Focus Adjustment for Repeatable Cylinder Structuring
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Solution Overview
Problem
Existing laser tools for structuring cylinder running surfaces face challenges in achieving high process reliability and repeatability in focal position adjustment, particularly due to manual intervention and potential angular misalignment of optical elements, which limits adaptability to different cylinder diameters and changes in focal position.
Innovation Solution
A laser tool design featuring a collimator movable by a drive system, allowing precise adjustment of the focal position without manual intervention, with a control device for parameter-controlled movement and a tilting device to compensate for angular misalignment, ensuring stable and repeatable laser beam guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment of optical elements is used, then the focal position can be adjusted, but the process reliability and repeatability deteriorate due to potential angular misalignment and lack of adaptability
Solution Approach 1:
The system performs automatic focus adjustment without requiring manual intervention. The control device automatically controls the drive to move the collimator to the target position based on stored parameters, making the system self-sufficient in maintaining optimal focus settings.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated electromechanical system. A drive mechanism (electromagnetic, electro-pneumatic, or electro-hydraulic) substitutes for manual screw adjustment, enabling precise and repeatable positioning of the collimator through electronic control rather than manual operation.
2Manufacturing precision
If manual screw adjustment is used, then the optical element can be clamped at various positions, but the repeatability deteriorates when setting to the same cylinder diameter
Solution Approach 1:
The control device uses feedback from a measuring system to verify and adjust the collimator position. The measuring system detects the actual position of the collimator, and the control device compares it with the target position, making corrections as needed to ensure precise and repeatable focal positioning.
Solution Approach 2:
The system stores parameter sets for different cylinder diameters and automatically retrieves and applies the appropriate parameters when processing different workpieces. This enables the collimator to be positioned with high repeatability for the same cylinder diameter by consistently applying the same calibrated parameters.
3Adaptability or versatility
If manual adjustment is used, then the focal position can be set, but the adaptability to different cylinder diameters and focal position changes deteriorates
Solution Approach 1:
The control device is designed to handle multiple cylinder diameters and processing requirements through stored parameter sets. A single automated system replaces multiple manual adjustment procedures, providing universal adaptability across different workpiece sizes while reducing overall system complexity through integration.
Solution Approach 2:
The collimator position is made dynamically adjustable through the drive mechanism, allowing the system to adapt to different cylinder diameters and focal position requirements during operation. The automated system can quickly reposition the collimator based on changing processing conditions, providing dynamic adaptability rather than static manual settings.
4Measurement precision
If automated drive system is used, then the focal position adjustment precision improves, but the device complexity increases
Solution Approach 1:
The control device serves as an intermediary between the measuring system and the drive mechanism. It processes measurement data, determines the required position adjustments, and controls the drive accordingly, thereby coordinating the complex interactions between measurement and actuation components while maintaining system manageability.
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 precise and repeatable adjustment of the focal position for different cylinder diameters, improving processing reliability and quality, while reducing the risk of misalignment and enhancing adaptability, thus optimizing the laser tool's performance and cost-effectiveness.
Implementation Method 1
a collimator (11) that produces a parallel course of the laser beams from the laser source
Implementation Method 2
a lens (12) arranged inside a rotatable spindle (13). The parallel laser beams from the collimator are passed through this lens and then deflected onto the material surface
Data Source
AI summary
In order to create a laser tool, in particular for the structuring of cylinder running surfaces, that offers the possibility of adjusting the focal position of the laser beam with high process reliability and with high repeatability, it is provided that the laser tool has a laser source for producing laser beams, a collimator for producing a parallel course of the laser beams from the laser source, which are passed through a lens that is located within a rotatable spindle, wherein an optical device for deflecting the laser beams onto a material surface is attached to an end of the spindle facing away from the laser source, wherein the collimator is movable parallel to the laser beam by means of a drive.