Laser Machining Optics With Dynamic Beam Shaping for Variable Workpieces
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Solution Overview
Problem
Conventional laser machining systems with fixed optical images of the laser beam suffer from compromised cut quality and feed rate for varying workpiece materials and thicknesses, particularly at medium to high laser powers, due to rigid beam parameters that cannot be dynamically adjusted.
Innovation Solution
A machining apparatus with a stationary laser beam guiding device featuring a movable surface that adjusts the focal length and beam parameter product of the machining laser beam over time, enabling both static and dynamic beam shaping, allowing for flexible intensity distributions and focal length modifications without moving the entire beam guiding device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed optical image of the laser beam is used, then the device structure is simple, but the cut quality and feed rate are compromised for varying workpiece materials and thicknesses
Solution Approach 1:
The patent implements dynamic beam shaping by continuously moving the laser beam at high frequencies (100 Hz to 10 kHz) to achieve time-averaged power distributions. This dynamic approach allows the fixed optical system to adapt to different workpiece materials and thicknesses by varying the beam movement patterns, effectively providing adaptability without requiring multiple fixed optical configurations.
Solution Approach 2:
The patent changes the beam parameter product dynamically through high-frequency beam movement. By varying the movement amplitude, frequency, and pattern of the laser beam, the effective beam parameters are adjusted to match different machining requirements for various materials and thicknesses, maintaining adaptability while keeping the optical hardware fixed.
2Adaptability or versatility
If zoom optics are used to change the imaging ratio, then the focal length can be adjusted for different workpieces, but the device complexity increases
Solution Approach 1:
The patent replaces mechanical zoom optics with a stationary optical system combined with dynamic beam shaping. Instead of physically moving or changing optical elements to adjust focal length, the system uses high-frequency beam movement to achieve the same effect, substituting mechanical complexity with dynamic control.
Solution Approach 2:
The patent uses dynamic beam movement to achieve focal length adjustment functionality without physical zoom optics. By controlling the amplitude and frequency of beam oscillation, the effective focal characteristics are adjusted dynamically, providing the same adaptability as zoom optics but with a fixed, simpler optical train.
3Adaptability or versatility
If the entire beam guiding device is moved for beam shaping, then beam parameters can be adjusted, but the device size and complexity increase
Solution Approach 1:
The patent extracts the beam shaping function from the physical movement of the entire beam guiding device. Instead of moving the whole device, only the beam direction is dynamically adjusted through small angular movements, separating the beam guiding function from the beam shaping function and eliminating the need for large-scale mechanical movements.
Solution Approach 2:
The patent implements beam shaping through dynamic angular adjustment of the beam path using small, rapid movements rather than moving the entire device. This dynamic beam steering approach achieves the same result with minimal displacement, dramatically reducing the volume and complexity of moving components.
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 allows for high-frequency dynamic movement of the laser beam, enabling precise control over beam shaping and focal length adjustments, improving cut quality and feed rate across different materials and thicknesses, and supporting laser powers up to 4 kW and above in a space-saving configuration.
Implementation Method 1
an optical system (20, 30) with: at least one optical unit (20) that adjusts the focal length of the optical system
Implementation Method 2
at least one stationary laser beam guiding device (22) with at least one movable surface, wherein the at least one movable surface can be adjusted such that it modifies the focal length
Implementation Method 3
an interface (14) for a machining laser source (16) for generating a machining laser beam (15)
Data Source
AI summary
A machining apparatus for laser machining a workpiece in a machining zone is provided, having an interface for a machining laser source for generating a machining laser beam with a direction of propagation; an outlet opening for the machining laser beam; and an optical system between the interface and the outlet opening, wherein the optical system has: at least one optical unit that adjusts the focal length of the optical system, and at least one stationary laser beam guiding device with at least one movable surface, wherein the at least one movable surface can be adjusted such that it modifies the focal length of the optical system and/or the beam parameter product of the machining laser beam integrated over time in at least one operating mode. Further provided is a method for laser machining a workpiece.