Laser Scanner Synchronization for Large and Curved Surface Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for processing large or curved surfaces using laser scanners are inefficient due to the limited scan field size and the need for precise repositioning, leading to visual and functional disturbances, increased downtime, and complex synchronization requirements between laser scanners and mechanical axes.
Innovation Solution
A method where a surface is moved relative to a laser scanner along a predetermined course using a movement mechanism, with a single position signal indicating the surface's position and orientation, allowing for synchronized processing without the need for additional position information transmission, utilizing a combination of linear and rotational axes with a 3D laser scanner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the surface is divided into several partial areas and repositioned for each area, then the limited scan field of the laser scanner can be utilized, but visual or functional disturbances appear in overlapping areas and processing downtime increases
Solution Approach 1:
The patent implements dynamic synchronization between the laser scanner and movement mechanism by having the laser scanner follow the actual position of the movement mechanism in real-time. Instead of static pre-planned paths, the laser scanner dynamically adjusts its scanning position based on the current position signal from the movement mechanism, allowing continuous processing without repositioning interruptions while maintaining precise control over the laser beam's position and orientation.
2Area of stationary object
If mechanical axes are used to reposition the workpiece for each sub-area, then the scan field limitation can be overcome, but the mechanical system requires very high precision to place partial surfaces exactly next to one another
Solution Approach 1:
The patent replaces the mechanical repositioning approach with a coordinated control system where the laser scanner electronically adjusts its scanning position based on position signals from the movement mechanism. This substitution of mechanical precision requirements with electronic control and real-time synchronization eliminates the need for extremely precise mechanical placement while still achieving continuous, high-quality surface processing across large areas.
3Productivity
If the laser scanner and mechanical axes are moved simultaneously, then continuous processing of large surfaces is enabled, but complex synchronization control is required
Solution Approach 1:
The patent implements a feedback-based synchronization system where the laser scanner receives position signals from the movement mechanism and uses these signals to determine its scanning position in real-time. This feedback loop ensures that the laser scanner automatically follows the movement mechanism's position without requiring complex centralized control, achieving continuous processing with relatively simple control architecture.
4Area of stationary object
If repeated repositioning is performed for each sub-area, then the limited scan field can be utilized, but downtime increases up to 33% of total processing time
Solution Approach 1:
The patent enables continuous useful action by having the laser scanner process the surface continuously without interruption while the movement mechanism moves the workpiece. The laser scanner receives real-time position signals and adjusts its scanning accordingly, eliminating all repositioning downtime and maintaining continuous laser processing throughout the entire surface treatment, thereby achieving 100% useful action time.
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
Ensures efficient and error-free processing of large and curved surfaces by simplifying synchronization and reducing downtime, while maintaining precise control over the laser beam's position and orientation, thereby improving processing efficiency and reducing visual and functional disturbances.
Implementation Method 1
the laser scanner can have a laser source whose laser beam is guided via movable mirrors. The direction in which the laser beam emerges from the laser scanner can then be adjusted by moving the mirrors
Implementation Method 2
A laser beam is guided over the surface using a laser scanner. The laser beam can then act on the surface and process it
Data Source
Figure 2
AI summary
The invention relates to a method and to a device for machining a surface by means of a laser scanner. The surface is moved by means of a movement mechanism during the scanning process. The movement mechanism outputs a position signal to the laser scanner, by means of which the current position and/or orientation of the surface relative to the laser scanner can be inferred. The laser scanner is then controlled in accordance with the position signal. The position signal is a single signal that indicates the progress of a course along which the surface is moved relative to the laser scanner.