Laser Beam Scanning for Curved-Track Heating Alignment
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Solution Overview
Problem
Existing laser heating systems face challenges in efficiently aligning and maintaining a laser spot with curved tracks during heating processes, often requiring mechanical adjustments that lead to wear and increased costs due to the need for physical rotation or pivoting of the laser head.
Innovation Solution
The method involves using a scanner to create a virtual effective spot with a two-dimensional energy distribution by repetitive two-dimensional scanning, allowing alignment with curved tracks through electronic control of the scanning pattern and mirrors, eliminating the need for mechanical rotation of the laser head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the laser head is mechanically rotated or pivoted to align the laser spot with curved tracks, then the alignment precision is improved, but the mechanical wear increases and system reliability deteriorates
Solution Approach 1:
The patent replaces the mechanical rotation/pivoting system with an electronic scanning system. The laser spot is steered along curved tracks using galvanometric mirrors or other scanning mechanisms that deflect the laser beam electronically, eliminating the need for mechanical rotation of the laser head and thereby reducing wear while maintaining alignment precision
Solution Approach 2:
The patent creates a virtual effective spot by rapidly scanning the laser beam along a scanning pattern that approximates the desired curved track. This virtual spot follows the curved path through coordinated scanning motion rather than physical rotation, achieving alignment without mechanical wear
2Measurement precision
If the laser head is mechanically rotated or pivoted to maintain alignment with curved tracks, then the alignment accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent eliminates the need for mechanical rotation degrees of freedom by using an electronic scanning system with galvanometric mirrors or similar devices. The scanning system, controlled by software, replaces complex mechanical pivot mechanisms, reducing device complexity while maintaining alignment accuracy through electronic control
Solution Approach 2:
The patent uses dynamic scanning patterns that adapt to curved tracks. The scanning system dynamically adjusts the laser spot position along curved paths by modifying the scanning mirror angles in real-time, replacing static mechanical alignment mechanisms with dynamic electronic control
3Manufacturing precision
If fixed optics are used to shape and focus the laser beam with predetermined power distribution, then the manufacturing precision is improved, but the adaptability to different heating patterns deteriorates
Solution Approach 1:
The patent uses dynamic scanning patterns that can be rapidly reconfigured for different heating applications. Instead of fixed optics with predetermined power distributions, the system adapts the effective power distribution by varying the scanning speed, pattern, and duration at different locations, enabling both precision and versatility
Solution Approach 2:
The patent changes the scanning parameters (speed, pattern, amplitude, frequency) to achieve different effective power distributions on the workpiece. By modifying these operational parameters, the system can adapt to various heating patterns while maintaining manufacturing precision through controlled parameter adjustment
4Productivity
If the laser spot is rapidly scanned in two dimensions to create an effective spot, then the productivity is improved, but the complexity of controlling the scanning pattern increases
Solution Approach 1:
The patent uses a universal scanning control system that can generate various scanning patterns (linear, circular, radial, custom curves) using the same galvanometric mirror mechanism. This multi-functional controller achieves high productivity through rapid 2D scanning while managing complexity through a unified control architecture
Solution Approach 2:
The patent employs feedback control in the scanning system, where the actual laser spot position is monitored and compared with the desired position, and corrections are applied in real-time. This feedback mechanism simplifies the control of complex scanning patterns by automatically compensating for deviations, maintaining productivity while reducing control 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 simplifies the system, reduces mechanical wear, and enhances reliability by using electronic control to maintain alignment and adapt energy distribution dynamically, enabling efficient and rapid heating of large areas with improved productivity.
Implementation Method 1
heating an object by directing an energy beam, such as a light beam (typically a laser beam), onto the object
Data Source
AI summary
A method of heating a portion of an object includes the steps ofprojecting an energy beam onto a surface of the object so as to produce a primary spot on the surface, and repetitively scanning the beam in two dimensions in accordance with a scanning pattern so as to establish an effective spot on the surface, anddisplacing the effective spot in relation to the surface of the object to progressively heat the at least one selected portion of the object. Displacing the effective spot in relation to the surface of the object includes displacing the effective spot following a track featuring at least one change of direction.The effective spot is maintained aligned with the track by modifying operation of a scanner in correspondence with the at least one change of direction.