Laser Head Beam Wobbling Without Scanners or Deflecting Mirrors
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Solution Overview
Problem
Existing laser processing systems face challenges in efficiently inducing wobbling in laser beams for applications like laser cutting and welding, which can affect accuracy and efficiency due to the need for additional components like scanners or expensive deflecting mirrors.
Innovation Solution
The system employs a collimator with a plurality of lenses, where at least one lens is movable non-longitudinally relative to the optical axis to deflect the laser beam path, and another lens is configured to image the laser beam with a smaller beam diameter, allowing for the induction of wobbling without the need for external scanners or expensive mirrors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a scanner is used to generate beam wobbling, then the track width is increased, but the scanner influences sensors and affects weld path accuracy
Solution Approach 1:
The system separates the wobbling function from the scanning function by using independent components: a dedicated wobbling element (acousto-optic modulator or deformable mirror) creates the oscillating beam pattern, while a separate scanner handles the weld path tracking. This segmentation prevents the scanner from interfering with sensor accuracy while maintaining wide track width.
2Area of stationary object
If a fast oscillating deflecting mirror is used to induce wobbling, then the beam path is extended, but the system becomes expensive to implement
Solution Approach 1:
The patent replaces mechanical deflecting mirrors with non-mechanical or minimally mechanical solutions. Acousto-optic modulators use sound waves to diffract and steer the beam without moving parts, while deformable mirrors use electrostatic or magnetic fields to change surface curvature. This substitution eliminates expensive precision mechanical components while achieving the same beam oscillation effect.
3Power
If the laser beam diameter is kept small (0.2-0.3 mm), then the laser power is concentrated, but the track width is limited and spattering increases
Solution Approach 1:
The system applies periodic oscillation to the laser beam at frequencies of 200-500 Hz, creating a time-varying beam pattern that sweeps across a wider area. This periodic motion distributes the laser energy over a broader track width (0.6-1 mm) while maintaining sufficient power concentration at any given point during the oscillation cycle, thereby reducing spattering and facilitating gap bridging.
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 solution enables efficient wobbling of the laser beam, resulting in a wider track width that reduces spattering, facilitates bridging gaps, and allows for slower welding speeds while achieving greater welding depths with moderate laser power.
Implementation Method 1
at least one of the lenses is movable non-longitudinally relative to the optical axis to induce a deflection in a beam path of the laser beam relative to the optical axis
Implementation Method 2
The lenses are positioned along an optical axis from the laser source and are configured to collimate the laser beam to an exit diameter exiting the collimator
Implementation Method 3
at least one of the lenses is configured to image the laser beam therefrom with a beam diameter smaller than the exit beam diameter
Data Source
AI summary
A laser processing head for a laser beam uses actuators engaged with a delivery fiber end to deflect the fiber end relative to an optical axis. The laser beam from the fiber end is collimated by a collimator and is then focused by a focusing lens disposed in the head beyond the collimator to a focal point. The focal point of the laser beam is deflected from the optical axis in relation to the deflection of the fiber end. The fiber end and the actuators are housed in a sealed module. Deflection of the laser beam can be sensed by reflecting portion of the laser beam to a sensing element so a control system can monitor and control the fiber end's movement.