Laser Surface Texturing Path Planning for Collinear Track Segments
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Solution Overview
Problem
Laser machining methods, such as the skywriting method, face inefficiencies due to the 'pilgrim step' issue, where short machining segments close to each other lead to increased machining time as the laser needs to brake and re-accelerate, resulting in overlapping segments and reduced productivity.
Innovation Solution
A method that generates track segment data to maximize collinearity of laser track segments, allowing for longer sequences without interruption by integrating adjacent segments into common segment sequences, using image and model data to optimize laser path planning and control data generation, and employing sub-pixel interpolation and smoothing to enhance collinearity and reduce machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the skywriting method is used with traditional segment sequences, then the laser can be precisely guided over the workpiece, but the machining time increases significantly due to overlapping braking and starting segments
Solution Approach 1:
The patent divides the laser track into discrete segments and introduces a new segment type (travel segment) that allows the laser to move between machining segments without braking or accelerating. This segmentation enables independent optimization of each segment type, resolving the contradiction by separating the guidance function (maintained through controlled segments) from the time-consuming braking/accelerating cycles.
Solution Approach 2:
The patent performs preliminary planning of the laser path to identify and connect collinear machining segments before execution. By pre-processing the track data to maximize the number of collinear segments and minimize the need for braking/accelerating cycles, the system prepares an optimized path that reduces machining time while maintaining precision guidance through the structured segment sequence.
2Productivity
If the number of collinear laser track segments is increased, then the machining time is reduced, but the complexity of track segment data generation increases
Solution Approach 1:
The patent implements preliminary processing steps including sub-pixel interpolation and smoothing of track lines before segment generation. These pre-processing operations simplify the subsequent segmentation by creating smoother, more predictable track geometries that are easier to divide into collinear segments, thereby reducing the overall complexity of track segment data generation while enabling higher machining speeds.
Solution Approach 2:
The patent replaces complex mechanical path adjustments with computational methods. Instead of physically adjusting the laser path during machining to achieve collinearity, the system uses algorithms (sub-pixel interpolation, smoothing, and automated segment identification) to pre-calculate the optimal collinear segments, substituting computational complexity for mechanical complexity and enabling higher productivity.
3Manufacturing precision
If sub-pixel interpolation and smoothing are applied to track lines, then the collinearity of laser track segments is enhanced, but the data processing time increases
Solution Approach 1:
The patent applies sub-pixel interpolation and smoothing selectively rather than uniformly to all track lines. By identifying which track lines benefit most from these operations and applying them only to those cases, the system enhances collinearity where needed while minimizing unnecessary data processing time, resolving the contradiction between precision enhancement and processing efficiency.
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
Significantly reduces machining time while maintaining pattern quality by allowing the laser to travel longer segments at constant speed without braking or accelerating, thereby increasing efficiency and surface quality.
Implementation Method 1
Laser machining methods, such as the skywriting method... machining a workpiece surface by means of a laser... apply a texture pattern to at least one section of the workpiece surface
Data Source
AI summary
A method for machining at least one workpiece surface to apply a texture pattern to at least one section of the workpiece surface using a laser, based on image data specifying an image of the texture pattern applied to the at least one section of the workpiece surface and model data specifying a three-dimensional geometry of a surface form corresponding to the at least one section of the workpiece surface. Control data and segment data are generated based on the image and model data. The control data specify one or more segment sequences for each track line. Each segment sequence has track segments where the laser guides the texture pattern application to the at least one section of the workpiece surface; wherein the track segments of a segment sequence include one or more laser track segments where the laser travels in the switched-on state at a constant machining setpoint speed.