Laser Tool Path Planning for 3D Surface Texturing Patches
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Solution Overview
Problem
Current laser texturing machines face inefficiencies in machining time and surface quality due to limited focusing capacity and the need for numerous repositionings of the laser head when dealing with non-planar surfaces, leading to increased computation time and visible defects at patch boundaries.
Innovation Solution
A method is introduced to define a sequence of relative positionings of the laser head by computing closed patches with associated machining directions, validating these patches, and merging them to minimize repositioning and optimize machining angles, thereby reducing the number of laser head movements and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser head is repositioned frequently to machine non-planar surfaces with limited focusing capacity, then the marking precision is maintained, but the machining time increases significantly
Solution Approach 1:
The patent implements dynamic focus adjustment during the laser machining process. The focus position is varied continuously or in steps along the Z-axis to match the surface topology, allowing the laser to maintain optimal focus on curved surfaces without requiring frequent repositioning of the laser head, thus resolving the contradiction between precision and productivity
Solution Approach 2:
The patent changes the focus parameter (Z-position) dynamically during machining to adapt to surface curvature. By adjusting the focus distance according to the local surface geometry, the system maintains marking precision while reducing the need for mechanical repositioning, thereby increasing machining speed
2Productivity
If the number of laser head repositionings is reduced to decrease machining time, then productivity improves, but visible defects appear at patch boundaries
Solution Approach 1:
Dynamic focus adjustment ensures continuous optimal focus across patch boundaries by adapting the focus position to the local surface geometry. This eliminates the visible defects that would otherwise appear at boundaries where static focus settings would create discontinuities, allowing reduced repositioning without quality loss
Solution Approach 2:
By dynamically changing the focus parameter across patch boundaries according to surface topology, the patent eliminates discontinuities and visible defects. This allows the system to use fewer repositionings while maintaining uniform surface quality across the entire workpiece
3Manufacturing precision
If traditional patch-based machining is used with frequent repositioning, then the marking field constraints are satisfied, but computation time and device complexity increase
Solution Approach 1:
The patent dynamically adjusts the focus parameter during machining to extend the effective marking depth capability. This allows larger patches to be machined without violating marking field constraints, reducing the total number of patches and repositionings required, thereby simplifying the computation and reducing device complexity
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 significantly reduces machining time and enhances surface quality by limiting the number of laser head repositionings and minimizing machining angles relative to the surface normals, while maintaining compliance with the laser head's marking field and depth capabilities.
Implementation Method 1
The laser source 3 emits a laser ray 2, or more specifically a pulsed laser ray 2
Implementation Method 2
The laser ablation techniques used for the texturing work by sublimation of the material, generally metal, on the surface of the part
Implementation Method 3
The laser ray 2 is reflected by mirrors 4 and 5 which respectively make it possible to define, according to the axes X and Y of the Cartesian reference frame, the position of the point of projection of the laser ray on the surface of the part
Implementation Method 4
The laser ray also passes through a lens 6 with a dynamic focusing correction, commonly called F-theta lens. This device thus makes it possible to define the point of impact of the laser ray with the surface 7 of the part in a plane situated in the focal range considered
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a method for defining a sequence of relative positionings of a laser head 1 in relation to a part for the machining of a texture etched on the two-dimensional or three-dimensional surface 7 of the part modelled by a 3D meshing, comprising: - A step 100 of definition of N machining layers intended to be performed in succession, - A step 200 of definition, for each machining layer, of patches intended to be each machined from a single position of the laser head 1, comprising closed patches 15, the boundary of which is not affected by the laser ray 2, - A step 300 of validation of the closed patches 15, successively from the machining layer 1 to the machining layer N. Open patches whose boundary is affected by the laser ray 2 being defined for any areas which could not be machined from validated closed patches 15. Optionally, the method also comprises a step 400 of merging of the validated closed patches 15 into groups 50 of patches. Thus, the invention proposes a method which makes it possible to define a machining path which is particularly rapid to execute, and which provides excellent surface quality. The invention also proposes a computer program product and a computer-readable storage medium for implementing the method for defining a sequence of relative positionings of a laser head 1 in relation to a part.