Multi-Beam Laser Ablation for Composite Acoustic Panel Perforation
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Solution Overview
Problem
Current methods for perforating large numbers of small holes in acoustic panels, such as those used in aircraft propulsion systems, are inefficient and unreliable, as they require forming millions of holes with limited precision and consistency, especially when using laser systems.
Innovation Solution
A laser machining system that utilizes multiple lasers to concurrently form patterns of holes in a fiber-reinforced composite material by directing laser beams through a scanner head equipped with a laser beam multiplexer, allowing for simultaneous ablation of multiple apertures in a grouping-by-grouping fashion, reducing manufacturing time and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam is used to perforate the face sheet, then the laser system is simple to operate, but the manufacturing time is excessive when millions of holes must be formed
Solution Approach 1:
The patent divides the laser beam into multiple separate beams using a beam splitting system. Each beam can independently perforate different holes simultaneously, transforming a single-beam sequential process into a multi-beam parallel process, thereby dramatically increasing manufacturing speed without requiring multiple independent laser systems
Solution Approach 2:
The patent combines multiple laser beams into a single optical path using beam combining optics, allowing multiple beams to be directed from one laser source to different locations on the face sheet. This merging approach enables parallel hole formation while maintaining the simplicity of a single laser system
2Manufacturing precision
If rapid scanning laser cutting is used, then the laser beam can move quickly across the material, but consistency and reliability deteriorate when forming millions of small holes
Solution Approach 1:
The patent uses a fixed beam array configuration that pre-positions multiple laser beams at specific locations before processing begins. This preliminary arrangement of beams eliminates the need for rapid scanning movements during actual hole formation, ensuring consistent hole quality while reducing manufacturing time
Solution Approach 2:
The patent implements a dynamic beam steering system that can rapidly reposition the array of laser beams to different locations on the face sheet. This allows the system to maintain precise hole formation consistency while adapting to different processing locations, eliminating the time loss associated with moving a single beam sequentially
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 manufacturing time and ensures consistent, reliable formation of millions of holes with improved precision, addressing the inefficiencies of prior art methods by enabling simultaneous formation of multiple apertures, thus enhancing the production of acoustic panels for aircraft propulsion systems.
Implementation Method 1
Each laser beam ablates the composite object to form a respective one of the apertures in the pattern
Data Source
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AI summary
A manufacturing method is provided which utilizes a laser system (30). During an embodiment of this method, an object (24) is arranged relative to a head (34) of the laser system (30). A pattern of holes (22) are formed in the object (24) by ablating the object (24) with a plurality of laser beams (44) which are directed from the head (34).