Laser Processing Head Diaphragm for Larger Scan Fields
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Solution Overview
Problem
Laser processing heads face limitations in scan field due to beam deflection angles causing vignetting and thermal issues, leading to power losses and reduced usable scan areas, especially at high laser powers.
Innovation Solution
Incorporating a diaphragm within the laser processing head to reduce the laser beam's diameter by cutting off peripheral portions, thereby preventing beam edge collisions with optical elements and allowing larger scan fields while maintaining sufficient intensity for processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the deflection angle is increased to achieve a larger scan field, then the scan field size is improved, but vignetting occurs at optical element edges causing power loss and thermal heating
Solution Approach 1:
The diaphragm is positioned upstream in the optical path to pre-limit the laser beam diameter before it reaches the scanning module and focusing lens. This preliminary action prevents the beam from expanding to sizes that would cause vignetting at larger deflection angles, thereby enabling a larger scan field without power loss.
Solution Approach 2:
The invention changes the beam diameter parameter by using a diaphragm with a specific opening size (e.g., 2mm) to reduce the laser beam diameter from its original larger size. This parameter change allows the beam to maintain sufficient intensity while avoiding edge collisions during scanning, resolving the contradiction between scan field size and power loss.
2Area of stationary object
If the deflection angle is increased to achieve a larger scan field, then the scan field size is improved, but thermal heating of optical lenses occurs leading to focus shift and potential damage
Solution Approach 1:
The diaphragm is positioned upstream to pre-limit the beam diameter before it reaches the scanning module. This prevents excessive beam expansion during scanning that would cause the beam to hit lens edges and generate heat, thereby maintaining stable lens temperature and focus position across the expanded scan field.
Solution Approach 2:
The invention converts what would be harmful beam edges (which cause heating when they hit optical element edges) into a beneficial controlled beam profile. By using the diaphragm to define a smaller, well-contained beam diameter, the harmful peripheral portions are eliminated, and the remaining central portion provides sufficient intensity for processing without causing thermal damage.
3Area of stationary object
If the laser beam diameter is reduced by using a diaphragm, then the scan field is increased, but the beam intensity may be reduced
Solution Approach 1:
The invention optimizes the diaphragm opening size (e.g., 2mm diameter) to achieve the right balance: small enough to prevent vignetting and enable large scan fields, but large enough to maintain sufficient beam intensity for effective laser processing. This parameter optimization resolves the contradiction between scan field size and beam intensity.
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 diaphragm configuration increases the scan field by reducing beam collisions and power losses, allowing for larger processing areas without overheating or damaging optical components, even at high laser powers.
Implementation Method 1
at least one diaphragm configured to limit a diameter or cross-sectional area of the laser beam passing therethrough in order to increase a scan field of the laser beam
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A laser processing head (1) is presented. The laser processing head (1) includes a laser entry module (40) for introducing a laser beam (9); a collimating module (44) for collimating the laser beam (9); a scanning module (46) for deflecting the laser beam (9); a focusing module (50) for focusing the laser beam (9); and at least one diaphragm (100) for increasing a scan field (S) of the laser beam (9). The diaphragm (100) comprises a diaphragm body (104) and an opening (102), and is configured to limit a cross-sectional area (9c) of the laser beam (9) by the diaphragm body (104). The at least one diaphragm (100) is positioned optically downstream of the laser entry module (40) and optically upstream of the focusing module (50). A laser processing system (2) including the laser processing head (1) is also presented. Furthermore, a method for increasing a scan field (S) of the laser beam (9) is also provided.