Laser Tool Segment Boundary Alignment for Large Workpiece Machining
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Solution Overview
Problem
Existing laser machining methods for large workpieces face challenges with segment boundaries, resulting in geometry errors, connection errors, and uneven ablation due to varying angles of incidence and laser beam projections, leading to recognizable and potentially functional discontinuities.
Innovation Solution
The method involves maintaining a constant relative position between the workpiece and the laser tool, controlling machine parameters to ensure laser pulse hits align on a defined grid, equalizing angles of incidence between segments, and using adjustable optics to compensate for geometric variations, allowing for precise and symmetrical machining across segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the workpiece surface is separated into segments and machined from different relative positions, then large workpiece areas can be processed, but geometry errors and connection errors occur at segment boundaries
Solution Approach 1:
The workpiece surface is divided into multiple segments that are processed sequentially from different relative positions. This allows the laser tool to access and process large workpiece areas that would otherwise be unreachable from a single position, while maintaining controlled transition zones between segments.
Solution Approach 2:
Different processing parameters and angles of incidence are applied to different segments based on their local geometric characteristics. The machine parameters are specifically adapted for each segment to ensure uniform ablation properties and minimize geometry errors at segment boundaries.
2Area of stationary object
If segments are machined from different relative positions, then complete coverage of large surfaces is achieved, but connection errors and recognizable discontinuities appear at boundaries
Solution Approach 1:
The segment boundaries and processing paths are pre-planned and optimized before machining begins. The relative positions and angles of incidence for adjacent segments are predetermined to ensure seamless transitions and eliminate recognizable discontinuities at boundaries.
Solution Approach 2:
Machine parameters such as angle of incidence, laser power, and scanning speed are dynamically adjusted when transitioning between segments. These parameter changes compensate for geometric variations and maintain uniform ablation characteristics across segment boundaries.
3Adaptability or versatility
If the angle of incidence varies between segments, then optimal processing angles can be achieved for different surface orientations, but uneven ablation and projection errors occur
Solution Approach 1:
The angle of incidence is locally optimized for each segment based on its specific surface orientation and geometric characteristics. This allows the processing parameters to be adapted to local conditions while maintaining overall ablation uniformity through compensatory measures.
Solution Approach 2:
The machine parameters including angle of incidence are varied between segments to match the local surface geometry. By systematically changing these parameters, the method achieves optimal processing for different orientations while compensating for projection errors to maintain ablation uniformity.
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 reduces recognizable differences and functional errors at segment boundaries, ensuring precise and uniform ablation across large workpieces by maintaining consistent laser beam projections and angles of incidence, resulting in a smoother, more accurate machining process.
Implementation Method 1
The laser tool head 13 emits a laser beam 12 that hits the workpiece surface 10 and leads there to liquefaction and evaporation of the material
Implementation Method 2
leads there to liquefaction and evaporation of the material
Data Source
AI summary
In a method for machining a workpiece by a pulsed laser beam emanating from a tool head, the pulsed laser beam is guided across the workpiece surface in a constant relative position between workpiece and tool head, and the workpiece is machined consecutively in a first and another second relative position. The operating parameters in the second relative position are controlled such that one or more laser pulse hit locations generated in the second relative position have a defined position with reference to one or more laser pulse hit positions generated from the first relative position, particularly lie in a one- or two-dimensional grid defined by plural laser pulse hit positions on the workpiece surface made from the first relative position.