Laser Beam Rotation Control for Accurate Hole Machining
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Solution Overview
Problem
Conventional laser processing apparatuses face challenges in forming machined holes with desired shapes due to distortions in the shape of laser light condensed on the workpiece, leading to errors in the machined hole's shape.
Innovation Solution
A processing apparatus that includes a rotation unit to rotate the laser light's intensity distribution, a scanning unit to adjust the laser light's position and angle, and a control unit to compensate for shifts in the laser light's optical axis, ensuring accurate processing by interlocking the shifter and scanner units to maintain a consistent, circular intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser processing apparatus uses a movable mirror such as a galvano scanner and a condenser lens to scan and condense laser light on a workpiece, then various kinds of processes (for example, hole machining) can be performed on the workpiece, but if the shape of the laser light condensed on the workpiece is distorted, this influences the machined hole formed in the workpiece, and it is difficult to form the machined hole having a desired shape
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-distorting the laser light shape before it reaches the workpiece. The control unit calculates the required distortion in advance based on the optical system characteristics, and the shifter unit applies this pre-calculated distortion to the laser light beam. This preliminary distortion compensates for the expected distortion that will occur during condensation, ensuring that the final condensed shape on the workpiece is accurate and matches the desired shape.
Solution Approach 2:
The patent implements feedback by using a sensor unit to detect the actual shape of the laser light after condensation on the workpiece. The control unit receives this detection information and adjusts the shifter unit's distortion parameters based on the detected deviations. This closed-loop feedback system continuously monitors and corrects the laser light shape, ensuring high manufacturing precision for the machined holes.
2Manufacturing precision
If the laser light shape is distorted to compensate for optical system errors, then machined hole shape accuracy can be improved, but the complexity of the control system increases due to the need for calculating and applying compensatory distortion
Solution Approach 1:
The patent applies self-service by enabling the control unit to automatically calculate and determine the optimal distortion parameters without requiring manual intervention or complex external calibration systems. The control unit uses built-in algorithms to compute the necessary distortion based on the optical system's characteristics and automatically configures the shifter unit accordingly. This self-service capability reduces the need for complex external control mechanisms while maintaining high manufacturing precision.
3Manufacturing precision
If a shifter unit is added to the laser processing apparatus to adjust the laser light shape, then manufacturing precision can be improved, but the device complexity increases due to the additional component
Solution Approach 1:
The patent applies universality by designing the shifter unit to perform multiple functions simultaneously. The shifter unit not only distorts the laser light shape to compensate for optical errors but also can adjust the beam position and orientation. This multi-functional design allows a single additional component to address multiple aspects of laser light control, thereby improving manufacturing precision without proportionally increasing 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 apparatus effectively reduces angular and positional shifts, allowing for high-accuracy processing of workpieces by maintaining a consistent laser light shape, thereby minimizing errors in the machined hole's shape even when the laser light's optical axis fluctuates.
Implementation Method 1
a rotation unit configured to rotate with a rotation axis as a center, thereby rotating an intensity distribution of the laser light emitted therefrom with the rotation axis as a center
Implementation Method 2
a scanning unit configured to scan the laser light applied to the workpiece
Implementation Method 3
a control unit configured to irradiate the workpiece with the laser light while reducing at least one of an angular shift and a positional shift of the laser light entering the workpiece, which occur due to a shift between the rotation axis and a barycentric line of the laser light entering the rotation unit
Data Source
AI summary
A processing apparatus that processes a workpiece by irradiating the workpiece with laser light, the apparatus including a rotation unit configured to rotate with a rotation axis as a center, thereby rotating an intensity distribution of the laser light emitted therefrom with the rotation axis as a center, a scanning unit configured to scan the laser light applied to the workpiece, and a control unit configured to irradiate the workpiece with the laser light while reducing at least one of an angular shift and a positional shift of the laser light entering the workpiece, which occur due to a shift between the rotation axis and a barycentric line of the laser light entering the rotation unit.