Laser Ablation Marking Head for High-Speed Packaging Web Accuracy
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Solution Overview
Problem
Existing systems for providing laser ablated marks on high-speed packaging material webs face limitations in precision and control, particularly due to the limited mobility of mirrors, which results in tilted marks and reduced accuracy at high speeds.
Innovation Solution
A laser ablation marking system with multiple individually controlled light outputs arranged in the cross-wise direction of the web, capable of emitting high-power light (60 W or higher) and controlled by a controller to maintain consistent angle and position, ensuring precise and accurate marking even at speeds above 400 m/min.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If moveable mirrors are used to divert the laser beam in x-y directions, then the laser can mark the packaging material, but the limited mobility of the mirrors results in tilted marks and reduced accuracy at high speeds
Solution Approach 1:
The laser source is divided into multiple individually controllable light outputs (e.g., 16-32 outputs) arranged in the cross-wise direction. Each light output can be independently activated to create marks at different positions, eliminating the need for moving mirrors and enabling high-speed accurate marking.
Solution Approach 2:
The mechanical mirror system is replaced with an electronically controlled array of light outputs. Instead of physically moving mirrors to redirect the laser beam, the system uses multiple fixed light outputs that can be selectively activated, substituting mechanical movement with electronic control.
2Area of stationary object
If multiple lasers and associated mirrors are provided to extend the lateral dimensions of the ablated mark, then the marking coverage is increased, but the device complexity increases
Solution Approach 1:
Multiple light outputs are integrated into a single marking device head, arranged in a linear array in the cross-wise direction. This combines the functionality of multiple lasers and mirrors into one unified device, extending lateral marking capability without proportionally increasing overall system complexity.
Solution Approach 2:
Each light output in the array can serve multiple purposes: marking at different lateral positions, creating different mark patterns, and operating at different power levels. This multi-functionality reduces the need for separate marking devices for different marking requirements.
3Productivity
If the laser power is increased to 60 W or higher for high-speed marking, then the marking speed and precision are improved, but the energy consumption increases
Solution Approach 1:
Instead of using one high-power laser at full capacity, the system uses multiple light outputs where only the necessary number are activated at any given moment. Each output operates at optimized power levels (60-1000 W), providing sufficient energy for high-speed marking while reducing total energy consumption compared to a single high-power laser operating continuously.
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 system achieves high-precision, high-resolution laser ablated marks on packaging material webs moving at high speeds, maintaining accuracy and throughput, and enabling efficient marking of unique information and reference marks for alignment and traceability.
Implementation Method 1
Each light output is capable of emitting light to provide laser ablation
Implementation Method 2
controlling at least one of the light outputs to emit light in order to ablate selected parts of a coating substance arranged on a coated area on said web of packaging material
Data Source
AI summary
A laser ablation marking system for providing an image to a web of packaging material is provided. The marking system includes at least one marking device having at least one laser having a plurality of individually controlled light outputs arranged in the cross-wise direction of the web of packaging material, each light output having a power output of at least 60 W and being configured to emit light to provide laser ablation, and a controller being connected to the marking device and configured to control the light outputs based on the speed of the web of packaging material such that the emitted light will always hit the web of packaging material at the same angle.