Compact Laser Machining Head with Screw-Adjustable Alignment
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Solution Overview
Problem
Commercial laser-cutting and engraving stations are inadequate for fabric applications due to difficulties in achieving consistent and accurate focal adjustment, leading to yellowing of products caused by misalignment and poor fit of components, which results in uneven air flow and impurities on the lens.
Innovation Solution
A laser machining head element with a diagonal mirror assembly housing and a tubular sleeve with internal threads, an annular adapter for precise screw-fit alignment, and a nozzle with a 90-degree gas inlet for horizontal air flow, reducing focal length and ensuring proper alignment of the lens, beam, and nozzle aperture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a telescoping height-adjustment tube with manual set knob is used for focal adjustment, then the device structure is simple, but the manufacturing precision and reliability of focusing are insufficient for fabric applications
Solution Approach 1:
The patent replaces the manual mechanical telescoping adjustment system with a motorized drive mechanism that uses a leadscrew or rack-and-pinion system. This substitution transforms the manual focusing operation into an automated mechanical system controlled by a motor, thereby improving precision while maintaining reasonable structural complexity. The motorized system provides consistent, repeatable positioning that eliminates the imprecision of manual adjustment.
Solution Approach 2:
The patent implements a self-service focusing system where the controller automatically controls the motorized drive mechanism to position the nozzle at the correct height and focal length based on pre-programmed parameters or sensor feedback. This eliminates the need for manual operator intervention in the focusing process, ensuring consistent precision without requiring complex manual adjustment mechanisms.
2Device complexity
If a 3-4 inch laser beam path with focusing lens located high above the cutting bed is used, then the device structure is simple, but the alignment precision and consistency are insufficient for fabric cutting applications
Solution Approach 1:
The patent repositions the focusing lens from a high location above the cutting bed to a position much closer to the cutting surface, effectively changing the spatial dimension of the optical path. This dimensional change reduces the beam path length from 3-4 inches to a much shorter distance, thereby improving alignment precision and reducing the sensitivity to misalignment that causes yellowing in fabric applications.
3Ease of manufacture
If diagonal mirror assembly with poor interference fit and grub screws is used for component mounting, then the ease of manufacture is improved, but the reliability and consistency of alignment deteriorate over time
Solution Approach 1:
The patent extracts and eliminates the problematic diagonal mirror assembly with poor interference fit and grub screws from the design. Instead, it employs a integrated mounting structure where components are securely attached using robust screw fittings that maintain consistent alignment. This extraction of the flawed subsystem and replacement with a more reliable mounting approach ensures long-term alignment stability without sacrificing manufacturability.
4Ease of manufacture
If air nozzle shooting air at an angle into the cylinder is used, then the ease of manufacture is improved, but harmful factors such as air loss and lens contamination increase
Solution Approach 1:
The patent inverts the air flow direction from shooting air at an angle upward into the cylinder to directing air flow horizontally or downward away from the lens and cylinder interior. This inversion of the air nozzle orientation eliminates the harmful effects of air loss through the fitting and prevents impurities from being blown onto the lens, thereby reducing contamination and cleaning requirements while maintaining manufacturing simplicity.
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 easier, more consistent, and reliable focal adjustment, eliminating yellowing by maintaining proper alignment and simplifying lens cleaning, while being cost-effective and adaptable to fabric variations.
Implementation Method 1
a diagonal mirror assembly having a housing with a laser inlet and an orthogonal laser outlet, and a reflecting mirror adjustably seated inside the housing for directing laser light from the inlet into the outlet
Implementation Method 2
The lens cylinder 14 includes a telescoping height-adjustment tube 15 containing an internal focusing lens and mount
Data Source
AI summary
An improved laser-machining head unit for fabric comprising a diagonal mirror assembly with a tubular sleeve extending downward to an internally threaded distal tip. An annular adapter is provided with an externally-threaded male fining at one end and an internally-threaded receptacle at an opposing end. The externally-threaded male fitting of the adapter is adjustably screw-threaded into the internally threaded distal tip of the tubular sleeve. A laser nozzle has a frusto-conical tip and an annular collar Cm attachment to the adapter, the collar being externally threaded and fixedly screw-inserted into the internally-threaded receptacle of the adapter. In addition, there is a gas inlet affixed to the collar of the laser nozzle for introducing gas at a 90-degree angle thereto. The screw-adjustable configuration ensures proper alignment at all times of the lens, the beam and the nozzle aperture, and air stream.