Laser Scanner and XY Stage Synchronization for Large Workpieces
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Solution Overview
Problem
Existing laser machining systems face limitations in throughput and accuracy due to the limited Field Of View (FOV) of laser scanners and the need for complex, expensive controllers to synchronize laser scanners and XY stages, especially when dealing with large workpieces and multiple scanners.
Innovation Solution
A method where one scanner controller acts as a master to synchronize and derive path commands for both the scanner and the XY stage, using separate clock rates and applying corrections to ensure precise movement and firing of the laser beam, with a bridge connecting different real-time networks to facilitate data transfer between the scanner and stage controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser scanner is used to move the laser beam at high speed, then throughput is improved, but the working area is limited to the Field Of View (FOV) of the scanner
Solution Approach 1:
The system divides the overall machining task into two coordinated components: the laser scanner handles high-speed processing within its FOV, while the XY stage moves the workpiece to present different areas sequentially. This segmentation allows each component to operate within its optimal performance range, combining high throughput with extended working area.
Solution Approach 2:
The laser scanner is effectively nested within the XY stage system. The scanner operates within its limited FOV while the XY stage provides the broader contextual movement, creating a nested operational structure where the faster scanner is contained within the slower, larger-range stage system.
2Manufacturing precision
If the XY stage moves the workpiece at low speed, then positioning accuracy is improved, but throughput is reduced
Solution Approach 1:
The motion control is segmented between two systems: the XY stage provides accurate, low-speed positioning for precision, while the laser scanner delivers high-speed beam movement for throughput. The master scanner controller coordinates both systems so they operate in complementary speed ranges.
Solution Approach 2:
The system dynamically adjusts the operational roles of the XY stage and laser scanner based on the machining requirements. The stage moves slowly for positioning accuracy when needed, while the scanner moves quickly for high-speed processing, creating a dynamic system that adapts speed to functional requirements.
3Reliability
If a single controller manages both the XY stage and laser scanner, then synchronization is improved, but device complexity and cost increase
Solution Approach 1:
The control functions of both the XY stage and laser scanner are merged into a single master scanner controller. This unified controller generates and synchronizes path commands for both systems, ensuring coordinated operation while consolidating control architecture rather than using separate independent controllers.
Solution Approach 2:
The master scanner controller is designed with multi-functionality, serving both as the scanner controller and the XY stage controller. This universal controller handles multiple functions that would traditionally require separate dedicated controllers, reducing overall system complexity while maintaining synchronization.
4Productivity
If multiple laser scanners are used with one XY stage, then throughput is increased, but synchronization complexity increases
Solution Approach 1:
Multiple scanner controllers are merged into a hierarchical structure where one master scanner controller coordinates all scanners and the XY stage. This consolidation allows multiple scanners to operate simultaneously with unified synchronization, managing complexity through a single master controller rather than requiring independent coordination of each scanner.
Solution Approach 2:
The control system is segmented into a master scanner controller that handles global coordination and multiple scanner controllers that handle individual scanner operations. This segmentation distributes complexity appropriately, with the master handling synchronization across all scanners and stages, while individual scanners focus on their own beam control.
Data Source
AI summary
A laser machining device comprises a movable stage which is controlled by a stage controller. A laser produces a beam for machining and the beam is scanned over the part using a laser scanner under control of the laser scanner. The scanner controller controls the stage controller to synchronize movements of the stage with movements of the scanner. The stage may carry the part to be machined or the scanner.