Energy Beam Scan Supervision for High-Speed Pattern Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current scanner technology for energy beam processing apparatuses, such as laser systems, struggles to maintain precise scanning patterns at high speeds, leading to deviations in the actual scanning pattern, which can result in incorrect processing of objects and safety hazards due to potential beam misalignment.
Innovation Solution
A method and system that utilize encoders to measure and compare the actual scanning pattern of an energy beam with a predetermined threshold area, allowing for real-time monitoring and adjustment to ensure the energy beam follows the intended pattern, thereby preventing incorrect processing and safety risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high speed scanning is implemented, then productivity is improved, but manufacturing precision deteriorates due to deviations in the actual scanning pattern
Solution Approach 1:
The system continuously monitors the actual scanning pattern using encoders on the scanner mirrors and compares it with the predetermined scanning pattern. This feedback loop allows real-time detection of deviations and enables corrective actions to maintain manufacturing precision even at high scanning speeds.
Solution Approach 2:
The patent replaces direct mechanical measurement of the scanning pattern with optical/electronic measurement using encoders on the mirrors. This substitution allows for more precise and faster measurement of the scanning pattern, enabling high-speed scanning while maintaining accuracy through electronic feedback rather than mechanical constraints.
2Productivity
If scanner operates at maximum supported speed, then productivity is improved, but reliability deteriorates due to scanner breakdowns and mirror failures
Solution Approach 1:
The system performs preliminary monitoring of the scanning pattern continuously during operation. By detecting deviations before they lead to complete scanner failure or safety incidents, the system can take preventive actions such as reducing speed or shutting down, thereby maintaining reliability while operating at high speeds.
Solution Approach 2:
Continuous feedback from the encoders allows the control system to monitor scanner performance in real-time. When deviations indicate impending failure or unsafe conditions, the system can respond immediately, preventing reliability deterioration while maintaining high-speed operation within safe parameters.
3Manufacturing precision
If scanner makes small rotations to follow precise scanning pattern, then manufacturing precision is improved, but speed deteriorates due to scanner limitations
Solution Approach 1:
The encoder-based feedback system measures the actual mirror positions and scanning pattern deviations in real-time. This allows the control system to make precise, small adjustments to maintain accuracy without being constrained by the scanner's mechanical speed limitations, as the feedback enables corrective actions at the control level rather than requiring mechanical speed increases.
Data Source
AI summary
A method for supervision of a scan of an energy beam includes the following steps: providing an apparatus configured to provide the energy beam and a scanner to scan the energy beam, the scanner having two mirrors; operating the apparatus and the scanner such that the energy beam is provided while it is scanned according to a predetermined scanning pattern; determining, at least one processor of a computer device or system, an actual scanning pattern of the energy beam, when both the apparatus and the scanner are operated, by processing measurements provided by encoders of the two mirrors; and comparing, the at least one processor, the actual scanning pattern with a predetermined threshold area. A system for supervision of a scan of an energy beam includes an apparatus to provide the energy beam and a scanner to scan the laser beam, the scanner having two mirrors, each having at least an encoder; and a computing device or system with at least one processor.