Laser Web Handling Layout for Stable Beam Position
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Solution Overview
Problem
Conventional laser-processing systems for thin, flexible workpieces face challenges due to bulky handling systems that occupy valuable space and disrupt the laser processing beam position due to web-handling roll acceleration and deceleration.
Innovation Solution
A compact workpiece handling system is integrated into the laser-processing apparatus, featuring movable shuttle assemblies and web tensioning mechanisms to maintain web tension and minimize disturbance to the laser processing beam, with components like unwind and rewind spindles and web biasing systems decoupled from the support structure to reduce reaction forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional handling systems with multiple idler rollers, turn rollers, and web-tensioning dancer rollers are used, then workpiece handling capability is provided, but system footprint becomes bulky and valuable manufacturing floor space is consumed
Solution Approach 1:
The patent combines multiple workpiece handling functions (unwinding, tensioning, guiding, and rewinding) into a single integrated shuttle assembly that moves laterally between supply and rewind positions. This merging of functions eliminates the need for separate idler rollers, turn rollers, and dancer rollers distributed throughout the system, thereby reducing the overall system footprint while maintaining complete workpiece handling capability.
Solution Approach 2:
The patent employs a dynamic shuttle assembly that laterally moves between the supply end and rewind end positions rather than using fixed handling components throughout the system. This dynamic repositioning allows the same handling mechanisms to serve multiple functions at different operational phases, reducing the static space requirements while maintaining adaptability for various workpiece handling needs.
2Area of stationary object
If workpiece handling systems are integrated into the structure supporting the laser-processing apparatus, then system footprint is reduced, but disturbance of the laser processing beam position occurs due to acceleration and deceleration of the web-handling rolls
Solution Approach 1:
The patent extracts the web-handling rolls (supply and rewind rolls) from the laser-processing support structure, mounting them instead on a separate movable shuttle assembly. This separation ensures that the acceleration and deceleration forces generated during web handling do not transmit to the laser-processing apparatus, thereby maintaining beam position precision while still achieving a compact integrated footprint.
Solution Approach 2:
The patent segments the system into distinct functional modules: the laser-processing apparatus remains as a stable, stationary unit while the web-handling functions are isolated in a separate movable shuttle assembly. This segmentation prevents mechanical coupling between the high-precision laser system and the dynamic web-handling system, eliminating vibration and position disturbance while maintaining overall system compactness.
3Stability of the object's composition
If web tensioning is maintained during laser processing, then web stability is improved, but web damage risk increases due to excessive tension forces
Solution Approach 1:
The patent incorporates a web tensioning system with feedback control that dynamically adjusts the applied tension based on real-time web position and processing conditions. This feedback mechanism ensures sufficient tension is maintained to prevent web instability and flutter during laser processing, while automatically reducing tension when the web is stationary or being handled, thereby preventing damage from excessive forces.
Solution Approach 2:
The patent employs variable tensioning parameters that are dynamically adjusted during different operational phases. During active laser processing, higher tension parameters are applied to ensure web stability and flatness. During web loading, unloading, and positioning phases, the tension parameters are reduced or eliminated, preventing web damage while maintaining stability only when necessary during the actual processing operation.
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
The solution allows for efficient, space-saving laser processing of flexible workpieces while maintaining web tension and minimizing disruptions to the laser beam, enhancing processing stability and reducing the risk of web damage.
Implementation Method 1
a laser source operative to generate beam of laser energy, wherein the beam of laser energy is propagatable along a beam path
Implementation Method 2
a web biasing system operative to apply a biasing force to the web material to maintain the web material in a desired state of tension
Data Source
AI summary
Numerous embodiments are disclosed. In one, a laser-processing apparatus includes a workpiece handling system having an unwind assembly including an unwind spindle operative to support an unwind material roll of a workpiece, and a rewind assembly including a rewind spindle operative to support a rewind material roll of the workpiece and receive the workpiece from the laser-processing apparatus. In another, a laser-processing apparatus includes a workpiece handling system having a web handling assembly attached to an upper structure configured to support an unwind spindle supporting a unwind material roll of a workpiece, wherein the web handling assembly is positioned within a space above the fixture. The laser-processing apparatus further includes a web tensioner assembly configured to apply a biasing force on the tensioning roller to maintain the workpiece in a desired state of tension.