Laser Focusing Head for Simultaneous Multi-Beam Heat Treatment
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Solution Overview
Problem
Conventional laser heat treatment using a single beam is inefficient for treating complex geometries like gear teeth and cutting edges, as it requires multiple passes, leading to heat interference and insufficient energy absorption due to unfavorable angles of incidence, especially below 45°, which reduces treatment effectiveness.
Innovation Solution
A laser focusing head that splits a single laser beam into multiple beams, redirecting them at optimal angles of incidence, such as 90°, to simultaneously treat multiple locations on a work piece, enhancing energy absorption and avoiding heat interference from subsequent passes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser beam is used to treat complex geometries like gear teeth, then the equipment complexity is low, but the treatment effectiveness deteriorates due to heat interference from multiple passes and insufficient energy absorption at unfavorable angles
Solution Approach 1:
The single laser beam is divided into multiple separate beams using beam splitting optics. Each beam independently treats a different surface of the gear tooth, eliminating heat interference between passes and ensuring consistent treatment quality on all flanks simultaneously
Solution Approach 2:
The laser beams are directed at the workpiece from multiple angular dimensions rather than a single angle. By treating surfaces at their optimal angles of incidence simultaneously, the system overcomes the limitation of single-angle treatment and improves energy absorption across complex geometries
2Device complexity
If a single laser beam treats multiple surfaces sequentially, then the device complexity is low, but the productivity deteriorates due to multiple passes requiring sequential treatment
Solution Approach 1:
The laser beam is segmented into multiple parallel beams that treat different surfaces simultaneously. This parallel processing approach eliminates sequential pass requirements, directly increasing treatment throughput for multi-surface components
Solution Approach 2:
Multiple treatment operations that would normally occur sequentially are merged into a single simultaneous operation. All gear tooth flanks receive treatment at the same time, converting a multi-step process into a single-step process
3Device complexity
If the laser beam is directed at cutting edges in the plane of the blade, then the device complexity is low, but the energy absorption deteriorates due to unfavorable angles of incidence below 45°
Solution Approach 1:
The laser beam is directed from a dimension perpendicular to the blade plane rather than within the plane. By approaching the cutting edge from above at a near-perpendicular angle, the system achieves optimal energy absorption while maintaining simple device configuration
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 improves the efficiency of laser heat treatment by allowing simultaneous treatment of complex geometries with improved energy absorption, resulting in greater surface coverage and treated volume, as demonstrated by increased case depth and feed rate in examples like corrugation rolls.
Implementation Method 1
A focus stage is in optical communication with the adapter stage and is arranged to receive the first light beam from the adapter stage and to focus the first light beam
Implementation Method 2
A beam splitting stage in optical communication with the focus stage is arranged to receive the focused first light beam and to split the focused first light beam into a plurality of second light beams
Implementation Method 3
the amount of light that is absorbed by the material is insufficient to effectively heat treat the material efficiently
Data Source
AI summary
An apparatus that divides a single laser beam into two or more beams that can be directed at an object, such as a work piece, to perform laser heat treatment is disclosed. An adapter stage is in optical communication with a light source, such as a laser source, and arranged to receive a light beam from the light source. A focus stage in optical communication with the adapter stage is arranged to receive the light beam from the adapter stage and to focus the light beam. A beam splitting stage in optical communication with the focus stage is arranged to receive the focused light beam and to split the focused light beam into a multiple light beams. A redirection stage in optical communication with the beam splitting stage is arranged to receive the multiple light beams and to direct them toward a plurality of target locations on the object.