Rotatable Optical Wedge Beam Shaping for Flexible Laser Machining
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Solution Overview
Problem
Existing laser machining devices lack flexibility in changing spot shapes during machining and have complex, non-compact beam-forming and deflecting optical systems, limiting their adaptability and efficiency.
Innovation Solution
A beam-forming and deflecting optical system using rotatable optical wedges or prisms, made from suitable materials like glass, which can be formed into diffractive optical elements, allowing for quick and adaptive beam shape changes by rotating the wedges relative to each other, enabling a compact and space-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional beam-forming optical systems are used to change spot shapes during machining, then spot shape adaptability is improved, but device complexity and size increase
Solution Approach 1:
The optical system is segmented into multiple independent optical wedges (at least two) arranged in sequence along the beam path. Each wedge can be independently rotated about the optical axis, allowing the laser beam to be divided and shaped into multiple spots or complex patterns. This segmentation enables flexible spot shape adaptation without requiring a complete replacement of the optical system, thus improving adaptability while maintaining manageable complexity.
Solution Approach 2:
The optical wedges are designed to be rotatable about the optical axis during the machining process. By dynamically adjusting the rotation angles of the wedges, the spot shape and distribution can be changed in real-time without interrupting the machining operation. This dynamic adjustment capability provides continuous adaptability while using a fixed, compact optical system configuration.
2Adaptability or versatility
If multiple optical elements are arranged to form complex beam shapes, then spot shape versatility is improved, but the physical size of the device increases
Solution Approach 1:
Instead of arranging multiple optical elements side-by-side in the transverse plane (which would increase device width and volume), the solution uses rotation about the optical axis (adding an angular dimension). The optical wedges are positioned in sequence along the beam path and achieve shape versatility through rotational adjustment, effectively using the angular dimension to create multiple spot configurations without increasing the physical footprint of the device.
3Device complexity
If fixed optical systems are used for laser machining, then device simplicity is maintained, but adaptability to different machining tasks is reduced
Solution Approach 1:
The optical system incorporates rotatable wedges that can be adjusted during machining operations. This dynamic capability allows the same physical system to adapt to different spot shape requirements for various machining tasks (such as welding, cutting, or surface treatment) without requiring multiple fixed optical systems, thereby maintaining relative simplicity while achieving versatility.
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 solution allows for rapid and flexible adjustment of laser beam shapes during machining, reducing the complexity and size of the machining device, enabling optimal adaptation to various machining tasks without interrupting the process, and providing improved mobility and precision.
Implementation Method 1
at least two optical elements, which are arranged one behind the other in the direction of a collimated laser beam and which are formed by wedges with a respective wedge angle
Data Source
AI summary
A beam-forming and deflecting optical system for a laser machining device includes at least two optical elements, which are arranged one behind the other in the direction of the laser beam and which are formed by wedges with respective wedge angles, wherein at least one optical element is connected to a drive for the rotation of the optical element about the optical axis, whereby an optical wedge can be rotated relative to the at least one other optical wedge. Also a method for machining a workpiece uses a collimated laser beam. In order to achieve different shapes of the laser beam on the workpiece, each of the optical wedges, which are arranged one behind the other, in each case cover only a part of the laser beam.