Laser Beam Positioning Assembly for Material Processing
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Solution Overview
Problem
Conventional high-speed laser beam positioning systems are limited by size and throughput in assembly line material processing applications, requiring larger optical elements that increase system size and reduce processing speed.
Innovation Solution
A laser beam positioning system with a first focusing element and smaller, electrically-driven reflective optical elements that focus and direct a laser beam to a workpiece, reducing beam dimensions and allowing for smaller, faster systems with maintained resolution, using a second focusing element to achieve a small focal spot size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional optical elements (beam expander, rotating mirrors, flat field focusing lens) are used in laser beam positioning systems, then the system can achieve focused beam delivery to workpieces, but the system size increases and processing speed decreases
Solution Approach 1:
The patent removes the beam expander from the conventional optical system, extracting only the essential focusing and beam directing functions. This elimination of the beam expander component directly reduces system size while maintaining the core functionality of delivering focused beams to workpieces at high speeds
Solution Approach 2:
The patent divides the laser beam path into distinct functional segments handled by separate optical elements (focusing lens, beam directing elements). This segmentation allows each component to be optimized for its specific function with smaller dimensions, contributing to overall system size reduction while maintaining processing speed
2Manufacturing precision
If larger optical elements are used to maintain beam focus and resolution, then manufacturing precision is maintained, but device complexity and system size increase
Solution Approach 1:
The patent applies local quality by using a focusing lens with specific focal length optimized for the laser wavelength and application requirements. Instead of using large optical elements throughout the system, the focusing function is concentrated in a single optimized lens that creates the desired focal spot size on the workpiece, thereby maintaining manufacturing precision while reducing overall device complexity
Solution Approach 2:
The patent replaces mechanical beam expansion mechanisms with optical focusing principles. By using a focusing lens to create a small focal spot directly, the system eliminates the need for complex mechanical adjustment mechanisms and large optical elements, thereby maintaining beam focus resolution while 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
The system achieves a smaller, faster, and more efficient laser processing system with reduced component size and mass, enabling higher acceleration and improved performance while maintaining desired beam intensity and resolution.
Implementation Method 1
a first focusing element in the beam path configured to focus the laser beam to a first focal point along the beam path
Implementation Method 2
first and second reflective optical elements in the beam path for reflecting the laser beam toward the material processing area
Implementation Method 3
a second focusing element in the beam path configured to focus the laser beam to a second focal point at or proximate to a workpiece in the material processing area
Data Source
AI summary
Laser beam positioning systems for material processing and methods for using such systems are disclosed herein. One embodiment of a laser-based material processing system, for example, can include (a) a radiation source configured to produce a laser beam and direct the beam along a beam path, and (b) a laser beam positioning assembly in the beam path. The laser beam positioning assembly can include a first focusing element, first and second reflective optical elements, and a second focusing element. The first focusing element can focus the laser beam to a first focal point between the first and second reflective optical elements. The first and second reflective optical elements can direct the laser beam toward a material processing area while the laser beam has a decreasing or increasing cross-sectional dimension. The second focusing element can focus the laser beam and direct the beam toward the material processing area.