Laser Surface Processing Synchronization
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Solution Overview
Problem
Existing laser processing methods struggle to achieve uniform processing of large and/or curved surfaces due to limitations in the scan field of laser scanners and the need for precise repositioning, leading to visual and functional disturbances, especially when mechanical axes are used to position workpieces beyond the scanner's field.
Innovation Solution
A method where the surface is shifted and/or rotated relative to the laser scanner in successive repositioning processes, synchronizing the movement of mechanical axes with the laser scanner to ensure continuous scanning, with acceleration and deceleration phases to maintain precise alignment and reduce spatial errors, and utilizing a 5-axis machine tool with encoder input for virtual rotation of the scan field to adapt to surface orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the scan field of the laser scanner is enlarged to process larger surfaces, then the processing area increases, but the precision and uniformity of laser processing deteriorates due to limited deflection angles and scanning accuracy
Solution Approach 1:
The patent divides the large surface into multiple sub-areas that can be processed sequentially. The laser scanner processes one sub-area at a time within its limited scan field, while mechanical axes reposition the workpiece to bring the next sub-area into the scan field. This segmentation allows maintaining high processing precision within each sub-area while covering a large total area.
Solution Approach 2:
The patent combines the limited scanning movement of the laser scanner in one dimension with the repositioning capability of mechanical axes in another dimension. By coordinating the scanner's deflection movements with the mechanical axes' repositioning of the workpiece, the system extends the effective processing area beyond the scanner's native scan field while maintaining precision through synchronized control.
2Area of stationary object
If mechanical axes are used to reposition the workpiece for processing areas beyond the scanner's field, then the processing area increases, but visual and functional disturbances occur due to imprecise positioning and repositioning
Solution Approach 1:
The patent employs feedback control where the actual position of the mechanical axes is continuously monitored and compared with the desired position. The control system adjusts the axes movements in real-time to compensate for deviations, ensuring that the workpiece is repositioned accurately to maintain uniform laser processing across the entire surface without visual or functional disturbances at transition areas.
Solution Approach 2:
The patent replaces purely mechanical positioning with a coordinated system that combines mechanical repositioning with optical scanning control. Instead of relying solely on mechanical axes precision, the system uses the laser scanner's precise beam positioning combined with controlled mechanical movements, reducing the burden on mechanical positioning precision and eliminating disturbances at repositioning boundaries.
3Productivity
If the laser scanner moves the beam quickly across the surface, then the processing speed increases, but the scan field size remains severely limited
Solution Approach 1:
The patent merges the high-speed scanning capability of the laser scanner with the repositioning capability of mechanical axes. The scanner maintains its fast beam movement for high productivity within its limited field, while the mechanical axes simultaneously reposition the workpiece to expand the overall processing area. This combination allows the system to achieve both high speed and large area coverage.
Solution Approach 2:
The patent ensures continuous processing by coordinating the laser scanner's beam movement with the mechanical axes' repositioning actions. The scanner processes one sub-area while the axes prepare the next sub-area for processing, minimizing idle time and maintaining continuous useful action throughout the entire surface, thereby achieving high productivity across large areas.
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 allows for uniform and error-reduced laser processing of large and curved surfaces by synchronizing the movement of mechanical axes with the laser scanner, reducing spatial errors and enabling continuous machining without visual or functional disturbances, and accommodating complex surface geometries through virtual rotation of the scan field.
Implementation Method 1
a laser beam is guided over the surface by means of a laser scanner (3). The surface (11) can be processed by the laser beam impinging on the surface
Data Source
Figure 1
Figure 2~4B
Figure 3
AI summary
The invention relates to a method for laser-processing a surface. A laser beam is guided over the surface by means of a laser scanner, and the surface is moved and/or rotated relative to the laser scanner in a plurality of sequential repositioning processes. During each repositioning process, the laser beam is deflected by the laser scanner along a directional path between a starting direction and an end direction over the surface. The surface is moved during each repositioning process at least in a positive acceleration phase, in which a speed of the surface relative to the laser scanner is increased, and a negative acceleration phase, which is carried out after the positive acceleration phase and in which the speed of the surface relative to the laser scanner is reduced to zero. When the speed reaches zero during the negative acceleration phase before the laser beam has reached the end direction, the speed increase during the positive acceleration phase of the subsequent repositioning process begins at the point in time when the laser beam reaches the end direction, and when the speed reaches zero during the negative acceleration phase after the laser beam has reached the end position, the speed increase during the positive acceleration phase of the subsequent repositioning process begins immediately after the speed has reached zero.