Modular Laser Processing System with Sliding Focus Mechanism
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Solution Overview
Problem
Current laser material processing systems are limited by their fixed workspace dimensions, restricting the size and thickness of materials that can be engraved, and are often cumbersome, expensive, and difficult to transport due to their monolithic designs, lacking versatility and modularity.
Innovation Solution
A modular laser processing system with a sliding focus mechanism that allows the focusing optic to move above the laser beam path, enabling processing of materials exceeding the chamber dimensions, and featuring interchangeable parts and attachments for customized functionality, such as engraving cylindrical surfaces or using automatic conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed focusing optic with a movable z table is used to accommodate varying workpiece thicknesses, then the system can process different material thicknesses, but the device complexity increases and the x-y workspace area is reduced
Solution Approach 1:
The patent applies dynamics by making the focusing optic itself movable rather than fixed. The focusing optic is mounted on a movable platform that can be positioned at different heights, allowing the system to accommodate varying workpiece thicknesses dynamically. This eliminates the need for a separate movable z table while maintaining the ability to adjust to different material thicknesses.
Solution Approach 2:
The patent resolves the workspace conflict by utilizing the vertical dimension (z-axis) for focusing optic movement rather than requiring horizontal workspace expansion. By allowing the focusing optic to move vertically above the work area, the system accommodates thick workpieces without reducing the x-y workspace area, effectively using another dimension to solve the contradiction.
2Reliability
If a monolithic laser engraving machine design is used, then the system provides a complete enclosed workspace, but the system becomes cumbersome and difficult to transport
Solution Approach 1:
The patent applies segmentation by dividing the laser engraving system into separate modular components: a base unit containing the laser source and control systems, and a removable housing that provides the enclosed workspace. This modular design allows the enclosed workspace functionality to be attached when needed and removed or folded when transport is required, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The patent makes the housing dynamic by designing it to be removable or foldable rather than permanently fixed. This allows the system to transition between a fully enclosed state for reliable operation and a disassembled or compact state for easy transport, addressing both requirements of the contradiction.
3Volume of moving object
If the focusing optic is positioned below the laser beam path, then the system maintains a compact structure, but the maximum workpiece thickness is limited
Solution Approach 1:
The patent resolves this contradiction by moving the focusing optic to a different spatial dimension - positioning it above the laser beam path rather than below. This vertical repositioning allows the focusing optic to accommodate thick workpieces by adjusting its height above the beam path, while the overall system footprint remains compact because the movement is in the vertical dimension rather than requiring horizontal space expansion.
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
Enables the processing of materials of virtually unlimited size and thickness, reduces manufacturing and assembly costs, and provides enhanced versatility and portability, allowing for a wide range of materials and applications without the need for multiple specialized systems.
Implementation Method 1
Laser material processing systems or laser engraving machines are capable of directing a laser in a controlled pattern
Implementation Method 2
the laser's energy may vaporize portions of the material or cut completely through it
Implementation Method 3
the top layer of the material may be burned or charred to produce patterns, images, or words
Implementation Method 4
a focusing optic fixed in the vertical up-down direction (z-axis or z space)
Data Source
AI summary
A laser material processing system comprises: a housing defining an engraving chamber, an xy laser beam steering system, and a non-telescoping sliding focus mechanism. The housing includes a removable bottom panel that allows processing of workpieces that exceed dimensions of the engraving chamber and allows stacking of the system on modular attachments for specialized functions. The focus mechanism includes a carriage mirror subassembly attached to the x-axis carriage, a sliding member moveably attached to the carriage mirror subassembly, and a focusing lens subassembly attached perpendicularly to the lower end of the sliding member. The carriage mirror subassembly and the focusing lens subassembly are configured to receive and focus a laser beam to a focal point. The focusing lens subassembly is adjusted along a z-axis by disengaging the locking component and vertically sliding the sliding member and is locked into a position by engaging the locking component with the sliding member.