Laser Machining Vision Correction for Solar Panel Scribing

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Solution Overview

Problem

Laser machining of thin film photovoltaic solar panels faces challenges such as variations in workpiece thickness and surface flatness, leading to inaccuracies in scribe line straightness, alignment, and uniformity due to changes in focus and demagnification, as well as angular pointing instability at long working distances.

Innovation Solution

The implementation of vision correction and tracking systems in laser machining systems, which include a moving optical head with beam delivery systems and sensors/cameras for real-time adjustment of scribe lines based on detected parameters, ensuring accurate and uniform scribing by compensating for workpiece variations and maintaining beam stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser machining is performed at high speed with long working distance, then productivity increases, but manufacturing precision deteriorates due to angular pointing instability and focus variations

Engineering Contradiction:

Improvescribing speedVSAvoidscribe line straightness and alignment

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs vision systems with cameras to detect scribe line positions and workpiece variations in real-time, feeding this information back to the control system which adjusts laser positioning and focusing parameters dynamically to maintain precision at high speeds

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical measurement and positioning systems with optical vision systems and software-based tracking algorithms, enabling non-contact, high-speed detection and correction of scribe line deviations without mechanical interference

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If working distance is increased for large area workpieces, then ease of operation improves, but manufacturing precision deteriorates due to focus variations and demagnification changes

Engineering Contradiction:

Improveaccess to large area workpiecesVSAvoidscribe line width and depth uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent uses dynamically adjustable focusing lenses and beam delivery systems that can change focal length and beam parameters in real-time based on detected workpiece topography and distance variations, maintaining consistent scribe quality across large areas

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent modifies laser beam parameters such as focal length, beam diameter, and power density dynamically during machining based on real-time vision feedback about workpiece surface variations and distance changes

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If vision correction and tracking systems are implemented, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improvescribe line alignment and uniformityVSAvoidsystem configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent integrates multiple functions including vision detection, scribe line tracking, workpiece topography mapping, and laser parameter control into a single unified system that performs multiple tasks simultaneously, reducing overall system complexity despite enhanced capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables high-speed, accurate scribing of solar panels with reduced waste area, improving precision and throughput while maintaining alignment and uniformity of scribe lines, even on large, non-planar workpieces.

Implementation Method 1

laser machining systems and methods may be used to scribe one or more lines in a workpiece

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

laser machining systems and methods are commonly used to machine various types of materials and structures

Methodology Applied

Scientific EffectLaser heating: Heating

Implementation Method 3

vision correction and tracking systems... include a moving optical head with beam delivery systems and sensors/cameras for real-time adjustment

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20200039002A1Laser Machining Systems and Methods with Vision Correction and/or Tracking

Publication Date: 2020.02.06 IPG PHOTONICS CORP

AI summary

Vision correction and tracking systems may be used in laser machining systems and methods to improve the accuracy of the machining. The laser machining systems and methods may be used to scribe one or more lines in large flat workpieces such as solar panels. In particular, laser machining systems and methods may be used to scribe lines in thin film photovoltaic (PV) solar panels with accuracy, high speed and reduced cost. The vision correction and/or tracking systems may be used to provide scribe line alignment and uniformity based on detected parameters of the scribe lines and/or changes in the workpiece.