Laser Pattern Point Alignment Across Scanning Fields
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Solution Overview
Problem
Existing methods for creating pattern figures on workpieces using laser ablation struggle with seamless transitions and clean merging of pattern elements across different scanning fields, leading to visible joins and geometric limitations in large-area patterns.
Innovation Solution
A method and device that align and actuate a laser device to introduce pattern points on a workpiece by reading position data, adjusting scanning fields, and using image acquisition to ensure smooth transitions between polylines, with adaptive spacing to maintain pattern integrity across multiple positions and scanning fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a laser device is used to create pattern figures on large-area workpieces by scanning across multiple fields, then the area coverage is improved, but visible joins and discontinuities appear at the boundaries between scanning fields
Solution Approach 1:
The pattern figure is divided into multiple segments corresponding to different scanning fields. Each scanning field processes a portion of the overall pattern, allowing the large-area workpiece to be covered while maintaining continuity through careful alignment and overlapping of adjacent segments at field boundaries.
Solution Approach 2:
The method determines the courses of polynomial curves at the boundaries between scanning fields in advance, before actual laser processing. This preliminary calculation ensures that when the laser scans across multiple fields, the pattern points align seamlessly at the boundaries, preventing visible joins and maintaining pattern continuity across the entire large-area workpiece.
2Device complexity
If the laser beam is guided over the workpiece surface within a limited working window, then the device complexity is reduced, but geometric limitations prevent seamless large-area patterning
Solution Approach 1:
The method extends the effective working area by moving the workpiece through multiple positions, each corresponding to a different scanning field. This approach to large-area patterning adds a temporal dimension to the processing sequence, allowing the laser to cover extensive areas while maintaining the simplicity of the original scanning mechanism at each position.
Solution Approach 2:
The method dynamically adjusts the workpiece position and orientation across multiple scanning fields. By coordinating the movement of the workpiece with the laser scanning process and calculating appropriate polynomial curves for each field boundary, the system achieves seamless large-area patterning while maintaining relatively simple laser guidance within each working window.
3Ease of manufacture
If pattern points are introduced at fixed intervals across scanning fields, then the manufacturing process is simplified, but discontinuities and visible joins appear at field boundaries
Solution Approach 1:
The method applies different spacing strategies to different regions of the pattern. Within each scanning field, pattern points may be distributed at regular intervals for simplicity. However, at the boundaries between scanning fields, the polynomial curve calculations ensure appropriate spacing and positioning to maintain continuity and uniformity across field transitions, creating local adaptations that preserve overall pattern quality.
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
Enables seamless and clean transitions of pattern figures across scanning fields, allowing for large-area patterns without visible joins, thereby overcoming geometric limitations and ensuring uniformity and visibility of the pattern.
Implementation Method 1
Pattern figures are generated for example in painted vehicle components via laser ablation
Data Source
AI summary
A method for creating a pattern figure formed of pattern points, in a workpiece, using a laser device of a machining device comprises reading in first position data, which define positions of first pattern points on the workpiece, wherein the first pattern points are associated with a first portion of a polyline of the pattern figure associated with the first pattern, introduction of the first pattern points into the workpiece taking place while the machining device is located in a first position, a detection of a course of an end of the first portion of the polyline, a continuation of the course of the end of the first portion of the polyline, and an introduction of second pattern points of a second portion of the polyline into the workpiece using the continued course, while the machining device is in a second position.