Opposed Laser Wire Machining With Alternating Beam Shielding
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Solution Overview
Problem
Existing laser processing methods for wires, particularly in large-scale production of electrical machine components, are inefficient in processing opposite sides quickly and reliably with minimal maintenance, as they require multiple cycles and expose expensive laser beam sources to radiation, leading to potential damage and increased maintenance needs.
Innovation Solution
A laser processing device with multiple laser beam sources arranged in a plane transverse to the wire, using a diaphragm device to alternate laser beam exposure and a gas flow system to manage particle removal, allowing simultaneous processing of opposite sides within a single cycle while protecting beam sources from radiation and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beam sources are arranged opposite each other to process opposite sides of the wire simultaneously, then productivity is improved, but the risk of laser beam sources exposing each other to radiation increases, leading to reduced reliability and increased maintenance requirements
Solution Approach 1:
A diaphragm device is introduced as an intermediary element between oppositely arranged laser beam sources. The diaphragm alternately blocks and transmits laser beams, preventing radiation exposure between opposing laser sources while enabling simultaneous processing of opposite wire sides. This mediator resolves the contradiction by allowing high productivity through simultaneous processing while protecting reliability by blocking harmful cross-radiation.
2Reliability
If laser processing is performed on opposite sides of the wire in separate cycles, then laser beam sources are protected from radiation exposure, but processing time increases, reducing productivity
Solution Approach 1:
The diaphragm device operates periodically, alternately blocking and transmitting laser beams in a cyclic manner. During each cycle, one laser beam is blocked while the other is transmitted, then they switch. This periodic action enables both laser beams to be active simultaneously for processing opposite wire sides, reducing total cycle time while the alternating blocking pattern protects laser sources from mutual radiation exposure.
Solution Approach 2:
By using multiple laser beam sources that operate simultaneously on opposite sides of the wire with alternating diaphragm control, the system achieves continuous useful action throughout the processing cycle. Both lasers are continuously active and contributing to processing, unlike sequential methods where one laser must wait for the other to complete. This continuity dramatically improves productivity while the diaphragm ensures continuous protection against cross-radiation.
3Manufacturing precision
If expensive industrial lasers are used for powerful laser processing, then manufacturing precision and processing capability are improved, but maintenance costs and complexity increase
Solution Approach 1:
The diaphragm device provides beforehand cushioning protection for expensive industrial laser sources by blocking harmful radiation from opposing lasers before it can reach and damage them. This preventive measure cushions the lasers against degradation and failure, extending their service life and reducing maintenance frequency and costs, thereby justifying the initial investment in high-power precision lasers.
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 significantly reduces cycle time, enhances reliability, and minimizes maintenance by protecting laser beam sources and efficiently managing particle removal, thereby improving the speed and efficiency of wire coating removal with reduced wear and tear on equipment.
Implementation Method 1
A laser beam is focused on the wire surface. This removes the insulation material in the form of particles that flake off the wire at high speed
Implementation Method 2
Other laser processing methods, such as ablation, also generate material that should be removed from the processing area
Data Source
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AI summary
For the fast yet safe processing of a wire (70) during the series production of an electric machine, the invention provides a laser processing device (10) for laser processing of a wire (70), comprising a wire guide device (12), a first laser beam source (14a) for emitting a first laser beam into the processing area (22), a second laser beam source (14b) for emitting a second laser beam, wherein the first laser beam source (14a) and the second laser beam source (14b) are arranged in opposite directions to each other in order to direct the first and the second laser beam to opposite sides of a point (110) of the wire (70) to be processed, and an aperture device (16) with a first aperture and a second aperture which are coupled and movable in such a way that alternately one of the first and second laser beams is allowed to pass through into the processing area (22) and the other is blocked.