Multi-Channel Laser Machining System for 3D Objects
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Solution Overview
Problem
Current laser machining systems face inefficiencies in machining three-dimensional objects due to the need for mechanical rotation of the object and multiple laser beams, which results in low throughput and precision issues, especially when dealing with complex shapes and orientations.
Innovation Solution
The use of a two-dimensional optical scanner and a laser beam allows for machining from different orientations without rotating the object or splitting the laser beam, enabling rapid machining and precise control of laser motion using a galvanometer scanning head and associated mirrors, lenses, and a camera for machine vision alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical rotation of the object is used to machine all surfaces, then all surfaces can be machined, but throughput decreases and precision issues arise
Solution Approach 1:
Instead of rotating the workpiece to access all surfaces, the patent inverts the approach by keeping the workpiece stationary and rotating the laser beam delivery system. The laser beam is steered through multiple optical channels with different orientations, allowing the laser to approach and machine all surfaces of the workpiece from various angles without mechanical rotation of the object itself.
Solution Approach 2:
The patent introduces multiple optical channels (first, second, and third channels) with different spatial orientations to machine different portions of the workpiece. By adding this dimensional aspect of multi-directional optical access, the system can machine all surfaces simultaneously or sequentially without mechanical rotation, thereby maintaining high throughput while achieving complete surface coverage.
2Adaptability or versatility
If multiple laser beams are used to machine different portions, then all surfaces can be machined, but device complexity increases
Solution Approach 1:
The patent divides the optical path into multiple segmented channels (first, second, and third optical channels), each with its own mirrors and lenses. Each channel is optimized for machining specific portions of the workpiece from different orientations. This segmentation allows a single laser beam to be delivered through different optical paths to machine various surfaces, avoiding the need for multiple simultaneous laser beams while maintaining the ability to access all surfaces.
Solution Approach 2:
The single laser beam is designed to be universal by delivering it through multiple optical channels that can each target different portions of the workpiece. The laser beam serves multiple functions by being routed through different optical paths (channels) with different orientations, allowing one laser source to machine all surfaces of the workpiece without requiring multiple laser beams or complex multi-beam delivery systems.
3Adaptability or versatility
If mechanical rotation is used, then all surfaces can be accessed, but precision and alignment issues occur
Solution Approach 1:
The patent inverts the mechanical rotation approach by keeping the workpiece completely stationary and instead rotating/redirecting the laser beam through multiple optical channels. This eliminates mechanical alignment issues between the workpiece and laser system, as the workpiece remains in a fixed, precisely positioned location throughout the machining process while the laser beam is steered to different surfaces through optical mirrors and lenses.
4Productivity
If object motion is minimized, then throughput improves, but machining all orientations becomes difficult
Solution Approach 1:
The patent adds the dimension of multiple optical channels with different spatial orientations to the system. By providing first, second, and third optical channels that approach the workpiece from different angles and directions, the system can machine all orientations of the workpiece while the workpiece remains stationary. This multi-dimensional optical access enables complete surface machining without any object motion, maintaining high throughput while achieving full orientational coverage.
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 enables rapid and precise machining of complex shapes from multiple directions with minimal motion of the object, improving throughput and reducing the need for mechanical alignment, thus enhancing the efficiency and accuracy of laser machining processes.
Implementation Method 1
Ablation is the removal of material from the surface of an object by vaporization, chipping, or other erosive processes. The term 'ablation' is often used in the context of laser ablation (i.e., laser machining), a process in which a laser dissolves bonds in a solid or sometimes liquid material.
Implementation Method 2
a two-dimensional optical scanner and a laser beam allows for machining from different orientations without rotating the object or splitting the laser beam, enabling rapid machining and precise control of laser motion using a galvanometer scanning head and associated mirrors
Implementation Method 3
a two-dimensional optical scanner and a laser beam allows for machining from different orientations without rotating the object or splitting the laser beam
Data Source
AI summary
A laser machining system for machining a work-piece includes a laser scanning head, external optical subsystems, and an image acquisition device. The external optical subsystems correspond to optical channels that include a first optical channel and a second optical channel. The laser scanning head controls an optical path so that a laser beam is directed and focused on the work-piece through the first optical channel and the second optical channel at different times. The first optical channel and the second optical channel correspond to respective specific portions of the work-piece to be machined by the laser beam. The image acquisition device is positioned to view the work-piece through the optical path. The image acquisition device acquires via the first optical channel one or more images of the work-piece to determine a displacement of the work-piece with reference to a best optical focus position of the second optical channel.