Laser Machining Head Aberration Optics for Stable Beam Shape
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Solution Overview
Problem
Conventional laser machining heads experience instability due to changes in energy intensity at the peripheral portions of laser light, leading to unstable machining processes such as keyhole defects and spatter generation.
Innovation Solution
Incorporation of an aberration optical system with a specific refractive power configuration and a collimating optical system to stabilize the beam shape, using an aberration lens to maintain constant lateral aberration regardless of divergence angle changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional optical system is used without aberration correction, then the structure is simple, but the energy intensity of peripheral portions changes with divergence angle, causing machining instability
Solution Approach 1:
The aberration optical system is designed with non-uniform refractive power distribution: the center region has no refractive power or very small refractive power (≤1/10 of collimating optical system), while the peripheral region has specific light collecting characteristics. This local differentiation corrects peripheral beam distortion without significantly affecting central beam quality, thereby stabilizing energy intensity distribution while maintaining reasonable structural complexity
Solution Approach 2:
The aberration optical system divides the lens aperture into two distinct functional regions: a center region and a peripheral region. Each region is optimized for its specific function - the center region maintains beam integrity while the peripheral region corrects divergence angle-dependent distortion. This segmentation allows independent optimization of each region's refractive characteristics to achieve overall beam stability
2Reliability
If the aberration optical system has strong refractive power to correct aberration, then beam shape stability improves, but the focal point position shifts significantly
Solution Approach 1:
By assigning different refractive power characteristics to different regions - the center region with negligible refractive power and the peripheral region with controlled light collecting characteristics - the system achieves beam shape stabilization without causing significant focal point shifts that would occur with uniform strong refractive power across the entire lens
Solution Approach 2:
The refractive power distribution is carefully controlled within specific parameter ranges: the center region refractive power is limited to ≤1/10 of the collimating optical system, while the peripheral region follows specific light collecting characteristics. These parameter constraints ensure beam shape stability is achieved without excessive focal point position changes
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
Stabilizes the machining process by maintaining consistent beam shape and reducing spatter, thereby achieving stable laser machining.
Implementation Method 1
an aberration optical system disposed at a position within a range in which laser light emitted toward a workpiece spreads in a propagation direction of the laser light, and causing aberration
Implementation Method 2
a collimating optical system through which the laser light propagates
Data Source
AI summary
A laser machining head includes: an aberration optical system disposed at a position within a range in which laser light emitted toward a workpiece spreads in a propagation direction of the laser light, and causing aberration; and a collimating optical system through which the laser light propagates. A center region of the aberration optical system has no refractive power or has refractive power with an absolute value equal to or less than 1/10 of refractive power of the collimating optical system. A peripheral region of the aberration optical system where a distance from the central axis exceeds the boundary value, has a light collecting characteristic in which when a light ray parallel to the central axis is incident on the peripheral region, the light ray at a position farther from the central axis has a shorter distance between the aberration optical system and a focal point of the light ray.